Modular mobile treatment and precooling apparatus, methods, and systems

ABSTRACT

An improved system and method for treating, precooling, handling, and packaging perishable products uses a mobile container enhanced with increased capacity refrigeration and air flow to recirculate functional substances including sanitizers, and ripening management and conditioning agents across the surface of perishable products during the precooling step. The mobile container is a prefabricated container or is modified from a standard intermodal container or over-the-road semi-trailer. The enhanced forced air and/or refrigeration equipment is contained within the container and/or mounted on the top and/or side exterior of the container and can accomplish rapid cooling. The mobile container can be located near harvest or facilities with no cooling assets. A combined system using conveyors and operational controls provides automated handling of the perishables from receiving, through precooling and treatment, through processing and packaging, preferably to a MAP process, and then to distribution.

TECHNICAL FIELD

The present invention relates to an improved system and method fortreating, precooling, and handling perishable products, as well asprocessing and packaging such products. Functional treatments, likesanitizing substances, are recirculated through pallets and across thesurface of the perishable product. The treatments are appliedsurrounding the process involved with precooling. Combining sanitizingwith cooling immediately after harvest solves major current problems byquickly reducing the level of mold and other micro-organisms on thesurface of perishables and then preventing cross-contamination ofperishables during the enhanced rapid cooling process. Thesecapabilities are not possible or practical in current commercial coolingfacilities. The improved system and process eliminates the continualintroduction of field contaminated product into the commercial facilityand prevents cross-contamination from cooling air that carry mold andother micro-organisms to the surface of perishables. The delivery of thetreatments via the improved system and apparatus may be continual,intermittent, pulsed, sequential, or otherwise staged to effect maximumanti-microbial efficacy. Water, used as the substance carrier, isintegrated with the humidity control system. Reducing dehydration orhydrating the perishable is accomplished by constantly replacing themoisture in the air lost as it is cooled. Substances can be added toenhance product quality, safety, value, shelf-life, and/or manage theconditioning or ripeness of the perishable product. The system andmethods involve the use of a refrigerated container or semi-trailermodified to add the refrigeration and air flow capability required foreffectively recirculating the substances and rapidly cooling theproduct, and use materials of construction compatible with the varioussanitizers and substances that can be used. Using a chassis with thecontainer or semi-trailer, the system is mobile and can be physicallymoved from a seasonal harvest location and/or a production or greenhouseoperation and then re-installed and used when the harvest location movesduring the year. As the container or trailer are isolated from thecommercial facility/warehouse, a wider range of sanitizers and otherfunctional substances can be safely used. The key components of thesystem for supplying refrigerations, substance treatments,humidification, and high capacity airflow are all modular and, thus,adaptable for various perishable and operational applications. Thesanitizing capabilities of these systems can augment currentsanitization, food, and worker safety programs prior to receivingproducts into facilities. These capabilities can be located at or nearerthe actual harvest and production location and/or a greenhouse operationto shorten the time to begin this critical processing step. Therefrigeration built-in with the modifications for cooling providescapacity benefits for the user to eliminate the need for fixedpre-cooling, reduce the need, size, and operating costs for fixed coldstorage and/or convert valuable space that is generally used within acold temperature facility for storage instead of pre-cooling. Along withthe systems for cooling and sanitizing the harvested, perishableproduct, additional systems and processes can be included to integrateproduct handling and/or product packaging into the overall system. Suchproduct handling and/or product packaging further involves the use ofmobile containers and/or semi-trailers modified to accommodate suchprocessing lines and/or packaging lines. The conceived product handlingsystem substantially improves the capability of the product handlingfrom harvest/receiving through distribution, allowing each step to becarried out in a more timely, effective and cost efficient manner.

BACKGROUND

Generally, perishable product is routinely harvested and processed inways that do not always yield exceptional quality, condition orripeness, and shelf life due to multiple root causes that originate withthe technology available and practiced by the grower/shipper. Perishableproduct that is packed in the field and/or a greenhouse in the finalconsumer package or market ready case is not cleaned, washed, orsanitized to reduce spoilage or pathogenic organisms that may be presenton the surface. Additionally, typical produce cooling and distributionfacilities operate seasonally during the climate driven growing andharvest seasons. These regional facilities are located within hours ofthe various harvest locations. The facilities have processing capacitiesaccording to their size, design and configuration. Seasonally, thesefacilities may be strained operationally as a result of the seasonalnature of growing and harvesting. Product is often transited for severalhours after harvest just to get to the cooling facility. Upon arrival,it may sit on the delivery truck awaiting to be received. It may thenwait again to be positioned for precooling. There is no precooling withfield and/or greenhouse packing. Packing houses typically provide noprecooling capability at all with a current purpose to just pack, ship,or transfer perishable products to cooling facilities. These operationalstrains delay getting the product to its intended shipping temperature.Harvest to cool time is one of the most critical process control points.Fruit, vegetable (produce), or cut flower respiration, which is a keyindicator for the shelf life of harvested products, is greatly reducedby cooling the product to its lowest possible temperature before chillinjury can occur (see, e.g., FIGS. 20 and 21). Produce demands timelyand efficient processing. Delays in cooling are typically the primaryroot cause of quality issues that show up downstream in the market. Adirect result is that frequently the perishable is harvested at a lessmature stage of ripeness with organoleptic properties that do not matchthe products' potential eating condition quality or consumers'expectations.

The facility/warehouse operations that are performing the delayedprecooling most often do not have rigorous cleaning and sanitizationduring the seasonal operation. As harvested products are brought intothe cooling facility from the fields some of these products bring withthem mold and micro-organisms contamination, and the contaminationlevels generally increase through the harvest season. Air is circulatedthroughout the cooling facility/warehouse and also forced across theperishables for precooling. Mold and other micro-organisms canaccumulate in this air and on the warehouse and/or coolingequipment/process surfaces. This results in further contamination of theperishable product from airborne mold and spoilage organisms pushedthrough pallets during precooling.

In addition, air that is circulating throughout the warehouse and alsoforced across the perishables is typically low in relative humidity, asthe cooling equipment condenses water from the air. This air, thus,dehydrates the perishable product(s) during precooling.

If the perishable product is sanitized before cooling, then mixed with acontaminated product in a contaminated cold room and/or contaminatedcooling air, any mold and micro-organisms removed during sanitizing willjust be added back to the perishable product. If the perishable productis sanitized after cooling, then the sanitizing process has to reduce aneven higher contamination load. In addition, separated steps ofsanitizing and precooling, product handling and product packaging, whilepossible, extend the overall process time and require additionalhandling and costs. Another key consideration is that when cooling airis shared within the cold storage warehouse with the precooling process,significant limitations are present that relate to operator safetyand/or equipment surface corrosion. Moreover, sanitizers andconditioning or ripeness management substances would not be permissiblein such a cold storage warehouse.

There, thus, remains a need for improved product processing that canprovide reduced harvest to cool time, clean and, preferably, cooling aircontaining sanitizer for reduced surface mold, spoilage, and pathogenicorganisms, humidified air to reduce dehydration or hydrate, conditioningor ripeness management, product handling and/or product packaging, whilerapidly achieving intended product temperature.

BRIEF SUMMARY OF THE INVENTION

According to one embodiment, the present invention provides an overallsystems approach to treat and cool perishable product to achieve ahigher quality product that will have extended shelf life fromdeterioration and decay. Shelf life issues are caused by delayed or poorprecooling and mold or other surface spoilage organisms present. Thesystem includes an overall strategy to select the proper sanitizingsubstances and application method. The system also includes precoolingair flow, cooling, and humidity methods and controls to achieve theintended shipping temperature with minimum dehydration. Whereas mostsanitizing processes within a production facility are intended toprovide only seconds to a few minutes of contact time with a sanitizer,this system leverages the one hour or more of precooling time to providean extended exposure period for sanitization. As a system, this thenenables the use of sanitization stages, steps or cycles, continual,intermittent or pulsed to achieve the intended microorganism reductionsafely without the sanitizer substance treatment negatively affectingthe perishable product. Additionally, the application of sanitizingduring precooling is unique to standard sanitizing processes thatinclude heating the surface of the product or using a sanitizer at anelevated temperature relative the produce item. The system can furthercombine a process line and/or a packaging line to complete theprocessing and/or packaging of the product for the consumer. Forexample, at least three product types can be handled according to thevarious systems of the invention. These product types include, e.g., (i)pre-packed product after harvesting, (ii) bulk packed product into aharvest container to supply to a packing line, and (iii) product packedinto a partial container that needs additional handling/processing stepsto complete the packing of the harvested product. The invention furtherprovides operators a flexible approach to shorten the number of handlingsteps and the time it takes to get the product to its intended statethat is ready for shipment.

According to another embodiment, the present invention includes anindependent apparatus for cooling a perishable product to its intendedtemperature using one of (i) a mobile container or (ii) a semi-trailerthat is modified to add high capacity refrigeration and high capacityairflow that is forced through pallets of cartons of product and/orvented packages with product. The one of (i) a mobile container or (ii)a semi-trailer includes at least one refrigeration source that isconfigured to supply a cooled airflow to the one of (i) a mobilecontainer or (ii) a semi-trailer that is directed across the pallets ofcartons of product and/or vented packages of product contained withinthe one of (i) a mobile container or (ii) a semi-trailer. The one of (i)a mobile container or (ii) a semi-trailer is configured to be movable soas to be relocated to a seasonal growing or production area foryear-round utilization.

According to another embodiment, the present invention includes anapparatus for sanitizing a perishable product in which sanitizingsubstances, inserted in stages, steps, cycles, continually,intermittently, or pulsed, are recirculated within air that flows acrossa surface of the perishable product with the effect of reducing at leastone of (i) pathogenic organisms or (ii) spoilage organisms that occur onthe surface of the perishable product. The apparatus comprises one of(a) a mobile container, (b) a semi-trailer, or (c) a prefabricatedcontainer (or trailer), which is modified to supply the treatments ofsanitizing and/or functional substances to the perishable product, withthe one of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container (or trailer) including at least one treatmentapplication system that is configured to supply the treatments ofsanitizing or functional substances, which can be dispensed to anultra-fine/fine micron size (e.g., ultra-fine is less than 0.01 micronsin size (e.g., gaseous molecules), extra fine is greater than 0.1microns in size but less than 1 micron (e.g., phages, smoke-likeparticulates, RNA-biologicals, etc.), super fine is greater than 1micron in size but less than 10 microns (e.g., substances that can beeasily suspended as airborne particulates and/or biologicals), very fineis greater than 10 microns in size and up to 100 microns (e.g.,practically airborne suspended substance particles), fine is greaterthan 100 microns in size but less than 1,000 microns (e.g., substancesthat will not remain suspended in air), and other less fine substances,which are greater than 1,000 microns in size and are generally verydifficult to suspend in air), within the recirculating air, or directedto the surface of the perishable product contained within the one of (i)a mobile container, (ii) a semi-trailer, or (iii) prefabricatedcontainer/trailer, and/or (iv) a substance treatment system prior to orin conjunction with any packing/packaging equipment contained in (i),(ii), or (iii).

According to yet another embodiment, the present invention includes anapparatus for managing the conditioning or ripeness of a perishableproduct in which specified amounts of ripening accelerating or reducingsubstances are introduced and recirculated with air that flows across asurface of the perishable product during precooling. The effect is toinitiate or reduce ripening to achieve a prescribed ripeness level andorganoleptic properties for delivery to the customer. The apparatuscomprises one of (a) a mobile container, (b) a semi-trailer, or (c) aprefabricated container (or trailer), which is modified to supply theconditioning or ripening management substances to the perishableproduct, with the one of (i) a mobile container, (ii) a semi-trailer, or(iii) a prefabricated container (or trailer) including at least onetreatment application system that is configured to supply theconditioning or ripening management substances to the surface of theperishable product contained within the one of (i) a mobile container,(ii) a semi-trailer, or (iii) a prefabricated container (or trailer).Conditioning is intended to achieve the target preferred organoleptictaste, smell, texture and otherwise eating quality. Conditioning orripening management substances can include ethylene or ethephon foraccelerating ripening or 1-MCP (1-Methylcyclopropene) or similarsubstances to reduce or delay the impact of ethylene and slow or stopripening.

According to an embodiment, the high capacity refrigeration provides (i)about 5,000 to about 50,000 Btu's of cooling capacity per hour perpallet of product, (ii) about 25,000 to about 45,000 Btu's of coolingcapacity per hour per pallet of product, and/or (iii) about 35,000 Btu'sof cooling capacity per hour per pallet of product.

According to an embodiment, the high capacity airflow provides (i) about200 to about 3,000 cubic feet per minute (cfm) of airflow per pallet ofproduct, (ii) about 500 to about 1,000 cfm of airflow per pallet ofproduct, and/or (iii) about 1,000 to 3,000 cfm per pallet of product.Due to the variability of the static pressure caused by the palletcontainers and produce packaging, air flow cfm flowing through thepallet is an estimate, which may be adjusted in the systems processcontrols to optimize the airflow.

According to an embodiment, airflow is directed horizontally throughsides of one or more pallets holding the perishable product.

According to an embodiment, the sanitizing substances are mixed with acarrier that includes one of air, industrial gas, water, or alcohol.According to one embodiment, the carrier is water and the mixture isvaporized or distributed via a very small droplet size using a deviceconsisting of at least one of ULV high pressure spray, an ultrasonichumidifier, a nebulizer, a hot fogger, or a cold fogger. The substancescan then be added to the air flow stream in stages, steps, continually,intermittently, cycles or pulsed to maximize efficacy.

According to an embodiment, the high velocity air flow recirculatingthrough the pallets aids in the creation of small droplet size and/ordispersement of the substances applied within the container. The use ofvarious techniques for creating, releasing, and distributing substancesinto the airflow to treat the perishable product are contemplated as animportant element of the system. Such techniques include, for example,the use of microbubbles released into the recirculated fan airflow thatwill more uniformly distribute the selected functional substances (usingpressurized N₂, CO₂, and/or pressurized air) to the surface of thepalletized products.

According to an embodiment, an environment inside the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer (or trailer) is controlled to add nitrogen or carbon dioxideto create an atmosphere in which alcohols, ethers or other flammable orhazardous substances can be safely used as part of the sanitizingprocess.

According to an embodiment, at least one of the conditioning or ripeningaccelerating substances is ethylene. According to an embodiment, theripening reducing substances added are 1-MCP (1-Methylcyclopropene) to(i) stop or delay the ripening of the perishable product or (ii) reduceeffects of ethylene. These substances can be applied at various levels,durations, or dwell times to impart a desired effect to condition theperishable to its intended organoleptic characteristics. The ripeningaccelerating substances cause the perishable, whether climacteric ornon-climacteric, to improve its softness, taste, and/or smell whenharvested less mature. Ripening suppression substances halt or slow theripening process when the organoleptic properties are already at or neartheir mature target. Thus, an adjustment in the rate or degree ofripeness is considered “conditioning.”

According to an embodiment, the present invention includes an apparatusto treat perishable products with an agent to impact the produceresponse to ethylene.

According to an embodiment of the apparatus, the conditioning orripening management substances are mixed with a carrier that includesone of air, industrial gas, water, or alcohol.

According to another embodiment, the present invention includes a methodfor treating a perishable product and/or a method of using the variousapparatus discussed herein.

According to an embodiment, the sanitizing substances include at leastone of ozone, hydrogen peroxide, ionized hydrogen peroxide, ozonatedwater, ionized water, peracetic acid, sodium hypochlorite, ionizedchlorinated water, and any other form(s) (including ionized and oxidizedforms) of these substances. In particular, electrochlorinated water (inall of its forms, including AEW, BEW, NEW, and/or SAEW), ionizedsubstances, oxidizing materials, and other sanitizingsubstances/treatment provides an effective sanitizer, while also being anon-hazardous chemical and safe for humans.

According to an embodiment, a functional treatment is applied. Accordingto one embodiment, the functional treatment comprises a substanceselected from the group consisting of: a sanitizer, a preservative, anantifungal, an essential oil, a reducing agent, a surfactant, ahumectant, a buffering agent, a mineral salt, alkali metal salts, anaroma, a flavoring agent, a sealing or coating substance, ananti-browning substance, an ethylene scavenger, hydrocolloid,cyclodextrins, lipids, metallic compounds, ethylene reducing compound,ethylene blocking compound, ethylene scavenging compound, a ripeningagent, a nutritional substance, a probiotic, de-greening or coloringsubstances, nanoparticles, phages, enzymes, and a sugar substance.According to another embodiment, the functional treatment comprises asubstance selected from the group consisting of: chlorine dioxide,hydrogen peroxide, ionized hydrogen peroxide, peracetic acid, ozone,ionized water, ethanol, isopropyl alcohol, limonene, lemon oil, orangeoil, grapefruit oil, rosemary oil, thyme oil, sunflower oil, otherfruit-derived oils, tea tree oil, cinnamon oil, eucalyptus oil,potassium oleate, sodium dodecyl sulfate (SDS), ascorbic acid, citricacid, sodium bicarbonate, potassium carbonate, calcium phosphate, linearterpenes, cyclic terpenes, alcohols, aldehydes, esters, ketones,lactones, thiols, lipase, rose oil, rose essence, and fruit essence,vitamins, minerals, flavonoids, flavor compounds, color compounds,essence, essential oil, sugar, THC or THC compounds, CBD or CBDcompounds, oxidizing materials, probiotics, phages, enzymes,pharmaceutical compounds, or biological compounds.

According to an embodiment, at least one protective coating is appliedto at least one of (i) one or more sidewalls of the container,semi-trailer, or prefabricated container (or trailer), (ii)refrigeration and/or air flow equipment, and (iii) any other materialsthat come in contact with sanitizing ingredients.

According to an embodiment, materials of construction used for therefrigeration and/or air flow equipment comprise stainless steel,coatings, or other materials compatible with highly active sanitizersubstances.

According to an embodiment, a shuttle conveyor is also provided to movepallets into and out of the modified container, semi-trailer, orprefabricated container (or trailer). According to one embodiment, theshuttle conveyor is an in-and-out design. According to anotherembodiment, the shuttle conveyor is a pass-through design in whichpallets are passed-through from one end to the other end of the modifiedcontainer, semi-trailer, or prefabricated container (or trailer).According to one embodiment, the shuttle conveyor is integrated with asecond shuttle conveyor that moves pallets to an MAP application system.

According to an embodiment, a shuttle conveyor is provided toautomatically transport at least one of cooled pallets and sanitizetreated pallets from the modified container, semi-trailer, orprefabricated container (or trailer) to an enclosure system and/or anMAP application system.

According to an embodiment, a mobile container, a semi-trailer, or aprefabricated container (or trailer), which is modified according to theinvention, is located outside of a cold storage facility, and therefrigeration is independent of the cold storage facility.

According to an embodiment, a mobile container, a semi-trailer, or aprefabricated container (or trailer), which is modified according to theinvention, is located outside of a cold storage facility, and a systemfor providing the refrigeration is able to connect and utilize a centralrefrigeration capacity of the cold storage facility.

According to an embodiment, a mobile container, a semi-trailer, or aprefabricated container (or trailer) that is modified according to theinvention, is positioned at a cold storage facility in a way in whichthe mobile container, semi-trailer, or prefabricated container (ortrailer) comprises a pass-through process into a cold storage area ofthe facility. According to one embodiment, pallets that contain theperishable product (a) enter the mobile container, semi-trailer, orprefabricated container (or trailer) from outside, (b) are cooled and/orsanitized within the mobile container, semi-trailer, or prefabricatedcontainer (or trailer), and (c) are removed from the mobile container,semi-trailer, or prefabricated container (or trailer) from inside thecold storage facility.

According to an embodiment, pallets can be re-ordered or mixed toprovide multiple perishable products within one pallet.

According to an embodiment, pallets coming from the pass-thru system canmove to a pallet conveyor system that automatically transports them to amodified atmosphere pallet (MAP) application system. Integration ofsanitizing, precooling, and then MAP provides the ultimate system forpreparation of the product, while offering improvements in overallprocess operation and reduction or elimination of the need for costlycentral warehouse operations. Further operational systems improvementscan include automated conveyors, robot pallet movers, automated stagingand pick areas for mixed shipments of produce commodities.

According to an embodiment, the modified mobile container, semi-trailer,or prefabricated container (or trailer) can be set up in close proximityto the harvest location to eliminate the transit time and handling stepsand thus, substantially shorten the time from harvest to cool toshipment.

According to an embodiment, a modified mobile container, semi-trailer,or prefabricated container (or trailer) can be located outside of a coldstorage facility and another modified mobile container, semi-trailer, orprefabricated container (or trailer) can be located as a pass-thrusystem. These systems can be used together or in sequence or in tandem.According to one embodiment, a sanitizing treatment can occur in onemodified mobile container, semi-trailer, or prefabricated container (ortrailer), and cooling can occur in the other modified mobile container,semi-trailer, or prefabricated container (or trailer). According toanother embodiment, a sanitizing treatment and cooling could occur inboth modified mobile containers, semi-trailers, or prefabricatedcontainers (or trailers). That is, the first modified mobile container,semi-trailer, or prefabricated container (or trailer) could provide asanitizing treatment and then the second modified mobile container,semi-trailer, or prefabricated container (or trailer) could cool theproduct, or vice versa. According to an embodiment, the first modifiedmobile container, semi-trailer, or prefabricated container (or trailer)could partially cool the product and the second modified mobilecontainer, semi-trailer, or prefabricated container (or trailer) couldcomplete the cooling to the intended temperature (e.g., around 32 to 34°F. or as may be appropriate for that commodity).

According to an embodiment, within each modified container,semi-trailer, or prefabricated container (or trailer), the sanitizingand cooling processes can be separated into stages or steps, where aperiodic amount of sanitizing ingredients is added and then cooling isconducted, or different sanitizing ingredients are added at differenttimes within the treatment and/or cooling process. As some of thesanitizing substances may be in a solution with water, it can beadvantageous to apply some treatments prior to cooling, when the airtemperature is able to support a higher moisture level. As such, the useof water to carry the substance can be integrated with the controlsystems to maintain maximum humidity to reduce dehydration or hydratethe perishable. In other cases, applying a water based substance tocooled product enables the sanitizer to condense on the surface of theperishable product and enable its active properties to impact thepathogenic or spoilage organisms present on the surface. Continuedcooling would then cause the surface moisture to evaporate to produce aclean, dry perishable surface.

According to an embodiment, at least one treatment application system isprovided that is configured to supply at least one of (a) sanitizingsubstances to a surface of the perishable product contained within theone of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container (or trailer), and (b) ripening substances to asurface of the perishable product contained within the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer (or trailer).

According to an embodiment, at least one refrigeration unit is providedthat is configured to supply and to direct a cooled airflow acrosspallets of cartons of product and/or vented packages of productcontained within the one of (i) a mobile container, (ii) a semi-trailer,or (iii) a prefabricated container (or trailer).

According to an embodiment, modifications to the mobile container (orprefabricated container (or trailer)) include adding refrigeration andair flow components along a wall on an inside of the mobile containerfor the cooling and/or treatment of at least 9 pallets of perishableproduct.

According to another embodiment, modifications to the semi-trailerinclude adding refrigeration and air flow components along a wall on aninside of the semi-trailer for the cooling and/or treatment of at least12 pallets of perishable product.

According to an embodiment, modifications to the mobile container (orprefabricated container (or trailer)) include adding a refrigeration andair flow unit within the mobile container to enable cooling andtreatment air for a container filled with at least 9 pallets ofperishable product.

According to another embodiment, modifications to the semi-trailerinclude adding a refrigeration and air flow unit within the semi-trailerto enable cooling and treatment air for a semi-trailer filled with atleast 12 pallets of perishable product.

According to an embodiment, modifications to the mobile container (orprefabricated container (or trailer)) include creating pop-out sidewallsand a roof mounted refrigeration unit to enable horizontal cooling andtreatment air for a container filled with at least 18 pallets ofperishable product. According to another embodiment, modifications tothe semi-trailer include creating pop-out sidewalls and a roof mountedrefrigeration unit to enable horizontal cooling and treatment air for asemi-trailer filled with at least 24 pallets of perishable product.

According to an embodiment, modifications to the mobile container (orprefabricated container (or trailer)) include attaching refrigerationunits to sidewalls of the mobile containers on the outside, thesidewalls having openings to enable horizontal air to cool and to treatat least 18 pallets of perishable product and to return the air to therefrigeration units. According to another embodiment, modifications tothe semi-trailer include attaching refrigeration units to sidewalls ofthe semi-trailer on the outside, the sidewalls having openings to enablehorizontal air to cool and to treat at least 24 pallets of perishableproduct and to return the air to the refrigeration units. According toone embodiment, the openings in the sidewalls have a vent design thatenables them to be opened and closed, and to adjust and direct the airflow to the pallets.

According to an embodiment, slot or expanded floor drains are includedthat are configured to be (i) sealed during cooling and/or sanitizingtreatments and (ii) opened to enable removal of any physical debris,water and/or cleaning solutions from daily cleaning and sanitation ofthe mobile container, semi-trailer, or prefabricated container (ortrailer).

According to an embodiment, a sanitizing treatment occurs before coolingin the mobile container, semi-trailer, or prefabricated container (ortrailer). According to another embodiment, a sanitizing treatment occursafter cooling in the mobile container, semi-trailer, or prefabricatedcontainer (or trailer). According to yet another embodiment, asanitizing treatment occurs during cooling in the mobile container,semi-trailer, or prefabricated container (or trailer).

According to an embodiment, multiple sanitizing treatments occur before,during, and/or after cooling. According to one embodiment, onesanitizing treatment occurs before, during, or after cooling, and then asecond sanitizing treatment occurs within a MAP (modified atmospherepallet) process, providing a unique and more effective dual sanitizingtreatment. The different treatments may be designed to have effects onthe different type of spoilage and/or pathogenic organisms that may bepresent on the surface of the perishable. The initial treatment cyclesmay weaken the microorganisms and then enable subsequent sanitizercycles to more completely deactivate or destroy them. The treatments mayhave a synergistic effect by the order or sequence of application.Treatments may be synchronized with the temperature of the perishableproduct during its cooling process.

According to an embodiment, a mechanism is further provided to movepallet closure-sealing pads to meet the pallets that have been loadedinto the one of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container (or trailer), to create a seal to create apositive air flow plenum and thus force air through the pallets insteadof around. According to one embodiment, the mechanism to move the palletclosure-sealing pads may be operated by at least one of hydraulic means(cylinders), at least one mechanical device or drive (such as a pulleyor servo motor), or air pressure (inflatable pads or cushions). Whenloading or unloading the container, the mechanism releases the pads andbacks away from the pallets.

According to an embodiment, the present invention provides an apparatusfor processing and cooling a perishable product to its intendedtemperature, with the apparatus comprising (A) one of (a) a mobilecontainer, (b) a semi-trailer, or (c) a prefabricated container (ortrailer), which is modified to add high capacity refrigeration and highcapacity airflow to perishable product, wherein the one of (i) a mobilecontainer, (ii) a semi-trailer, or (iii) a prefabricated container (ortrailer) includes at least one refrigeration source that is configuredto supply a cooled airflow to the one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container (or trailer) that isdirected across the perishable product contained within the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer (or trailer), and (B) one of (a) a mobile container, (b) asemi-trailer, or (c) a prefabricated container (or trailer), which ismodified to include a process line to sort and functionally treat theproduct.

According to one embodiment, the process line is configured to (i)transfer the product onto the line and (ii) remove any debris and/ordefects. According to another embodiment, the process line is furtherconfigured to apply at least one of (i) a wet or dry wash, (ii)sanitization, (iii) cooling (iv) air drying, or (v) a combinationthereof.

According to an embodiment, the apparatus further includes a packagingline to package the product into final consumer packages.

According to an embodiment, the perishable product includes one or moreof (i) pre-packed product after harvesting, (ii) bulk packed productinto a harvest container to supply to a packing line, and (iii) productpacked into a partial container that needs additionalhandling/processing steps to complete the packing of the harvestedproduct.

According to an embodiment, the apparatus further includes one of (a) amobile container, (b) a semi-trailer, or (c) a prefabricated container(or trailer), which is modified to supply sanitizing substances to theperishable product. According to another embodiment, the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer (or trailer), which is modified to add high capacityrefrigeration and high capacity airflow further includes at least onetreatment spraying system that is configured to supply at least one of(a) sanitizing substances to a surface of the perishable productcontained within the one of (i) a mobile container, (ii) a semi-trailer,or (iii) a prefabricated container (or trailer), which is modified toadd high capacity refrigeration and high capacity airflow, and (b)conditioning or ripeness management substances to a surface of theperishable product contained within the one of (i) a mobile container,(ii) a semi-trailer, or (iii) a prefabricated container (or trailer),which is modified to add high capacity refrigeration and high capacityairflow.

According to an embodiment, the apparatus further includes a shuttleconveyor to move perishable product into and out of (A) the one of (a) amobile container, (b) a semi-trailer, or (c) a prefabricated container(or trailer), which is modified to add high capacity refrigeration andhigh capacity airflow, and (B) the one of (a) a mobile container, (b) asemi-trailer, or (c) a prefabricated container (or trailer), which ismodified to include a process line to sort and functionally treat theproduct.

According to an embodiment, the apparatus further includes a secondaryone of (a) a mobile container, (b) a semi-trailer, or (c) aprefabricated container (or trailer), which is modified to add highcapacity refrigeration and high capacity airflow to perishable product,wherein the secondary one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container (or trailer) includesat least one refrigeration source that is configured to supply a cooledairflow to the secondary one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container (or trailer) that isdirected across the perishable product contained within the secondaryone of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container (or trailer). According to one embodiment, thesecondary one of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container (or trailer) further includes at least onetreatment spraying system that is configured to supply at least one of(a) sanitizing substances to a surface of the perishable productcontained within the secondary one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container (or trailer), and (b)conditioning or ripeness management substances to a surface of theperishable product contained within the secondary one of (i) a mobilecontainer, (ii) a semi-trailer, or (iii) a prefabricated container (ortrailer).

According to an embodiment, the apparatus further includes at least onemobile refrigerated container configured to provide cold storage for theperishable product prior to shipment.

According to an embodiment, the present invention provides an apparatusfor processing and cooling a perishable product to its intendedtemperature, with the apparatus comprising (A) one of (a) a mobilecontainer, (b) a semi-trailer, or (c) a prefabricated container (ortrailer), which is modified to add high capacity refrigeration and highcapacity airflow to perishable product, wherein the one of (i) a mobilecontainer, (ii) a semi-trailer, or (iii) a prefabricated container (ortrailer) includes at least one refrigeration source that is configuredto supply a cooled airflow to the one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container (or trailer) that isdirected across the perishable product contained within the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer (or trailer), and (B) one of (a) a mobile container, (b) asemi-trailer, or (iii) a prefabricated container (or trailer), which ismodified to include a packaging line to package the perishable productinto final consumer packages.

According to an embodiment, the apparatus further includes a processline to sort and functionally treat the product. According to anotherembodiment, the one of (a) a mobile container, (b) a semi-trailer, or(c) a prefabricated container (or trailer), which is modified to includea packaging line is further modified to include a process line to sortand functionally treat the product.

According to an embodiment, the perishable product includes one or moreof (i) pre-packed product after harvesting, (ii) bulk packed productinto a harvest container to supply to a packing line, and (iii) productpacked into a partial container that needs additionalhandling/processing steps to complete the packing of the harvestedproduct.

According to an embodiment, the perishable product includes one or moreof tomatoes, berries, cherries, meat products, fresh cut flowers,cannabis products, hemp products, a protein including meat, fish, foul,vegetable protein products, or other fruits and vegetables.

According to an embodiment, the present invention provides a method oftreating a perishable product using a plurality of independent modifiedcontainers, semi-trailers, or prefabricated containers (or trailers),with each independent modified container, semi-trailer, or prefabricatedcontainer (or trailer) of the plurality of independent modifiedcontainers, semi-trailers, or prefabricated containers (or trailers)being (a) modified to provide (i) high capacity refrigeration and highcapacity airflow, (ii) one or more sanitizing treatments, (iii) aconditioning or ripening management process, (iv) a humidification orhydration process, (v) a process line, (vi) a packaging line, or (vii) acombination of one or more of (i), (ii), (iii), (iv), (v), and (vi), and(b) used for (i) cooling, (ii) sanitizing, (iii) controlling or managinga conditioning or ripening process of the perishable product, (iv)sorting and functionally treating the product, (v) packaging the productinto final consumer packages, and (vi) a combination of one or more of(i), (ii), (iii), (iv), and (v).

According to an embodiment, a substance is directly applied using acarrier to a surface of the perishable product after harvesting andafter wet or dry washing of the perishable product, wherein apredetermined amount of the substance is applied to the surface tosubstantially coat, contact, or cover the surface; and wherein thesubstance is applied (i) before cooling of the perishable product, (ii)during cooling of the perishable product, or (iii) after cooling of theperishable product.

According to an embodiment, the perishable product is treated inside ofa packaging mechanism or a film forming mechanism, wherein the filmforming or packaging mechanism forms, seals, contains, or closes apackage around the perishable product, and the treatment occurs justprior to or simultaneous to when the package is formed around theperishable product.

According to one embodiment, the carrier is at least one of (i) aliquid, including ionized water or acidified water, (ii) a gas,including nitrogen or purified air, or (iii) combinations thereof.

According to an embodiment, the method further comprises incorporatingdetecting technology to direct substance treatment, with said technologybeing configured to (i) detect a surface area of the perishable productand adjusting an amount of the substance to be applied based on thedetected surface area of the perishable product; (ii) detect a defect onthe surface of the perishable product and applying the substance on thedefect on the surface of the perishable product; or (iii) detect anamount of the surface of the perishable product that is covered by asubstance, and directly reapplying the substance to the surface of theperishable product when the amount of the substance on the surface ofthe perishable product does not meet a predetermined value.

According to an embodiment, the substance is (i) selected from the groupconsisting of a sanitizer, an antifungal, an essential oil, a reducingagent, a surfactant, a humectant, a photosensitizer, a buffering agent,a mineral salt, an aroma, a sweetener or flavoring agent, a sealing orcoating substance, an anti-browning substance, an ethylene scavenger,ethylene blocking compound, a ripening agent, a nutritional substance, aprobiotic, a coloring, nano particles, phages, enzymes, sugar substance,an absorbent, a neutralizing agent, and an oxidizing agent, or (ii)selected from the group consisting of chlorine dioxide, hydrogenperoxide, peracetic acid, ozone, ionized water, lemon oil, orange oil,grapefruit oil, rosemary oil, sunflower oil, other fruit-derived oils,tea tree oil, cinnamon oil, eucalyptus oil, potassium oleate, sodiumdodecyl sulfate (SDS), ascorbic acid, citric acid, sodium bicarbonate,calcium phosphate, esters, linear terpenes, cyclic terpenes, alcohols,aldehydes, esters, ketones, lactones, thiols, rose oil, rose essence,air, and fruit essence.

According to one embodiment, the substance wet or dry washes, preventsmoisture loss of the perishable product, slows senescence of theperishable product, is a preservative, is comprised of ionized water orionized air, enhances color, enhances flavor, enhances aroma, enhancestexture of the perishable product, acts as a pH buffer, breaks downbiofilm on the surface, or combinations thereof.

According to an embodiment, the method further comprises directlyapplying a second substance which is different than the first substanceto the surface of the perishable product at asynchronous points prior tofinal packaging of the perishable product using a second carrier,wherein the second substance enhances the efficacy of the firstsubstance.

According to an embodiment, a method of using one of the above-describedapparatus is provided, in which at least one sensor is included with theone of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container (or trailer), wherein the at least one sensorperforms the following step (a) measuring the concentration of thesanitizing substances in the air to achieve a prescribed treatment, (b)measuring a presence of at least one airborne microorganism to determinewhen to conclude a sanitizing treatment cycle, (c) measuring a pulptemperature of the perishable product to determine when to conclude aprecooling cycle, (d) measuring the environment to determine when toconclude a venting and scrubbing of container gasses to enable removalof the product, and (e) measuring liquid condensate to determinetreatment for wastewater removal.

According to one embodiment, the present invention includes a systemadaptable for specific perishable products, packaging designs, andoperational flexibility, the system comprising at least one sanitizationapparatus, at least one cooling apparatus, at least one process line,and at least one packaging line, wherein air flow and cooling capacityis established to achieve a selected sanitizer recirculation and coolingrate, wherein the sanitizer and cooling processes are controlled fordesigned purposes and cycles, wherein the process line is configured toat least one of sort and functionally treat the perishable products, andwherein the packaging line is configured to package the products intofinal consumer packages.

According to an embodiment, humidity control to achieve minimumdehydration or hydration of the perishable is provided. According toanother embodiment, venting of gases and discharge of liquid condensateand substances is controlled for environmental concerns.

According to an embodiment, an enclosure and a modified atmospherepallet (MAP) application system is included with the system. Accordingto another embodiment, the system further includes at least one conveyorsystem to transport the perishable products between one or more of (i)the at least one sanitization apparatus, (ii) the at least one coolingapparatus, (iii) the at least one process line, (iv) the at least onepackaging line, and (v) the modified atmosphere pallet (MAP) applicationsystem.

According to one embodiment, the at least one sanitization apparatus andthe at least one cooling apparatus are combined into a single container.

According to an embodiment, the system further includes at least onemobile refrigerated container configured to provide cold storage for theperishable products prior to shipment.

According to an embodiment, the system further includes one or morerobotic pallets configured to transport the perishable products betweenone or more of (i) the at least one sanitization apparatus, (ii) the atleast one cooling apparatus, (iii) the at least one process line, and(iv) the at least one packaging line.

According to an embodiment, at least one of (i) the at least onesanitization apparatus and (ii) the at least one cooling apparatuscomprises a modified mobile container, semi-trailer, or prefabricatedcontainer (or trailer) that is configured to be setup in close proximityto a harvest or production location, such that a time from harvest tocool and shipment is substantially reduced by one or more hours up to 2days.

According to an embodiment, a process for treating and cooling thespecific perishable products is prescribed by regulating air flow fromlow to medium to high to achieve a desired dwell time for sanitizing andan intended cooling time.

According to an embodiment, an environment inside the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer (or trailer) is controlled to add nitrogen or carbon dioxideto create an atmosphere in which alcohols, ethers or other flammable orhazardous substances can be safely used as part of a sanitizing process.

According to an embodiment, at least one sensor is configured to supplydata to a control program of a controller in which a prescribed recipeis saved and the controller will adjust one or more parameters of theprocess to achieve at least one of a target cooling rate, relativehumidity, atmosphere level, substance treatment level, and microorganismcount reduction.

According to another embodiment, the present invention provides anoverall system for automated postharvest handling, treatment, precoolingand packaging for distribution of products supporting productionfacilities, including field, greenhouse, or indoor growing operations,the system comprising: (a) one or more mobile, portable modified orprefabricated containers, and (b) one or more conveyors, pallet shuttleapparatus, or robotic pallets interconnecting the one or more mobile,portable modified or prefabricated containers, wherein the system usesprescribed methods and programmed apparatus to provide productsanitizing, precooling, treating, handling, and packaging of theproducts from receiving to loading and shipping.

According to an embodiment, the one or more mobile, portable modified orprefabricated containers includes at least one pallet shuttle apparatusand comprises a pass-thru design to receive product directly from aprocessing or packing line and to deliver the product from a dischargeend directly to one of (i) an MAP system, (ii) a cold storage mobileunit, or (iii) loading and shipping.

According to one embodiment, the products include one or more of (i)pre-packed product after harvesting, (ii) bulk packed product into aharvest container to supply to a packing line, and (iii) product packedinto a partial container that needs additional handling/processing stepsto complete the packing of the harvested product.

According to yet another embodiment, the present invention provides anoverall system for automated postharvest handling, treatment, precoolingand preparation for distribution of palletized products supportingproduction facilities, including meat harvesting and processing, thesystem comprising: at least one (a) one or more mobile, portablemodified or prefabricated containers or trailers, (b) one or moreapparatus for substance treatments, and (c) one or more enhancedrefrigeration sources; and one or more conveyors or pallet shuttleapparatus interconnecting the at least one of (a) one or more mobile,portable modified or prefabricated containers or trailers, (b) one ormore apparatus for substance treatments, and (c) one or more enhancedrefrigeration sources, wherein the system uses prescribed methods andprogrammed apparatus to provide palletized product sanitizing,precooling, treating, and handling of the palletized products fromreceiving to loading and shipping.

According to an embodiment, at least one of (a) one or more mobile,portable modified or prefabricated containers and (b) one or morerefrigerated trailers includes at least one pallet shuttle apparatus andcomprises a pass-thru design to receive product directly from aprocessing or packing line and to deliver the product from a dischargeend directly to one of (i) an MAP system, (ii) a cold storage mobileunit, or (iii) loading and shipping.

According to an embodiment, the system(s) described herein provides amore efficient, timely, and cost-effective method for simultaneouslycooling and sanitizing perishable product (as the timely cooling stepand the timely sanitizing step both individually and together have asignificant impact on respiration and shelf-life).

According to an embodiment, an overall system(s) is provided forreceiving, sanitizing, treating, cooling, conditioning, handling,picking/packaging, and final preparation for shipping palletizedproducts. According to an embodiment, a modular mobile system includesmultiple improvements over the prior art with respect to, e.g., theintegrated handling of palletized products, more effective treatmentsand cooling, and efficiency improvements with respect to requiredresources including labor, time, energy, costs, and capital.

Additional features, advantages, and embodiments of the invention areset forth or apparent from consideration of the following detaileddescription, drawings and claims. Moreover, it is to be understood thatboth the foregoing summary of the invention and the following detaileddescription are exemplary and intended to provide further explanationwithout limiting the scope of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowchart of the current process to receive palletizedcontainers of perishable produce at a warehouse, cool the product to anintended temperature, and then moving the pallets to storage or aprocess to enclose the pallet and add a modified atmosphere.

FIG. 2 is a flowchart of an embodiment of the inventive process using amobile container designed to cool the berries to an intended temperaturein one (1) hour and also able to provide a sanitizing treatment duringthat time period.

FIG. 3 is a diagram illustrating an embodiment of a precooling system ofthe invention that is described by the flowchart in FIG. 2, using a40-foot-high cube reefer container, which could alternatively be a53-foot-high semi-trailer.

FIG. 4A is a diagram illustrating a top view of the precooling system ofFIG. 3.

FIG. 4B is a diagram illustrating a side or end view of the precoolingsystem of FIG. 4A.

FIG. 5 illustrates refrigerated intermodal container sizes that areavailable for use with embodiments of the invention, including theirinternal and external dimensions.

FIG. 6 illustrates refrigerated semi-trailer sizes and dimensions thatare available for use with embodiments of this invention.

FIG. 7 illustrates the air flow patterns in a conventional refrigeratedcontainer.

FIG. 8 illustrates the air flow patterns in a conventional refrigeratedsemi-trailer.

FIG. 9 is a diagram illustrating an alternative embodiment of aprecooling system of the invention using a 40-foot-high cube reefercontainer (or a 53-foot-high semi-trailer) to create pop-out sides thatcan provide sufficiently wide air supply plenum to increase the capacityof the unit.

FIG. 10A is a diagram illustrating a top view of the precooling systemof FIG. 9.

FIG. 10B is a diagram illustrating a side or end view of the precoolingsystem of FIG. 10A.

FIG. 11A is a diagram illustrating a top view of an alternativeembodiment of a precooling system of the invention that allows forclipping on the refrigeration and pressure air equipment onto the sidesof the container.

FIG. 11B is a diagram illustrating a side or end view of the precoolingsystem of FIG. 11A.

FIG. 11C is a diagram illustrating the modifications to the container ofFIGS. 11A and 11B, to cut out sections of the insulated wall to enableair to flow from the refrigeration unit to the pallets of perishableproduct and then return over the top of the pallet back to therefrigeration unit.

FIG. 12A is a flowchart of an embodiment of the inventive process whenthe container is used for sanitizing alone, and not cooling.

FIG. 12B is a flowchart of an embodiment of the inventive process inwhich a sanitizing treatment occurs before cooling and then a secondsanitizing treatment occurs within the MAP (modified atmosphere pallet)process.

FIG. 12C is a flowchart of an embodiment of the inventive process thatincludes a combination of multiple sanitizing treatments, with a firstsanitizing treatment occurring within a cooling step in a modifiedcontainer of the invention.

FIG. 13 is a diagram illustrating a typical or conventional cooling,storage, and shipping facility for perishable produce.

FIG. 14 is a diagram illustrating an embodiment of the invention inwhich containers are positioned for implementing a sanitizing treatmentand/or cooling before entry into the warehouse.

FIG. 15A is a diagram illustrating an embodiment of the invention inwhich the modified containers are used to cool and to apply thesanitizing treatment before storage in the warehouse, therebyeliminating the warehouse's current tarp cooling systems.

FIG. 15B is a diagram illustrating an embodiment of the invention inwhich two separate system designs are provided.

FIG. 16A is a diagram illustrating an embodiment of the invention inwhich the modified containers receive the warm product on the receivingdock, cool and sanitize the product, and then remove the product fromwithin the warehouse (e.g., a “pass-thru” system).

FIG. 16B is a diagram illustrating an embodiment of the invention inwhich an MAP application system is connected via a set of conveyors tocomplete the preparation of the cooled and ready for shipment pallet.

FIG. 16C is a diagram illustrating an embodiment of the invention inwhich a combination of exterior and pass-thru systems are used fortandem cooling, sanitizing treatment, and then MAP.

FIG. 17 is a flowchart of an embodiment of the inventive process usingthe mobile container system with exceptional refrigeration and air flowto more accurately and efficiently control the quality conditioning andripening of high climacteric perishable produce items.

FIG. 18 is a diagram illustrating an embodiment of the invention inwhich supplemental drains are included within the floor of theprecooling system or container for removal of debris remaining in thecontainer from field packed product.

FIG. 19 illustrates an embodiment of the invention that uses connectingautomated conveyors to physically move pallets from one location to thenext, including through doors, such as described in the variousembodiments for the invention.

FIG. 20 is a table of information from the University of California atDavis illustrating the dramatic impact of product temperature on rate ofrespiration.

FIG. 21 is a table from the USDA, Agricultural Marketing Service,illustrating safe minimal shipping temperatures for various fruits andvegetables.

FIG. 22 is a table illustrating recommended Temperature Range forvarious fruits and vegetables.

FIG. 23 is a flowchart of the current process to pack and transferpalletized containers of perishable product to a warehouse, cool theproduct to an intended temperature, moving the pallets to add a modifiedatmosphere (MAP), and then moving the pallets to storage where thepallets are maintained at 32° F. to 34° F. or another prescribedtemperature until shipment.

FIG. 24 is a flowchart of an embodiment of the inventive process usingmobile precooling at a harvest site, moving the pallets to add amodified atmosphere (MAP), and then moving the pallets to storage wherethe pallets are maintained at 32° F. to 34° F. until shipment.

FIG. 25 is a graph illustrating the differences in the time to cool aperishable product (e.g., strawberries) from the day of harvesting,between current cooling processes and the inventive precooling processaccording to an embodiment of the invention.

FIG. 26 is a table comparing the various properties of a harvestedperishable product (e.g., strawberry) with respect to current coolingprocesses (i.e., “Centralized Regional Whse”) and the inventive processaccording to embodiments of the invention.

FIG. 27 is a diagram illustrating an embodiment of the invention inwhich a separate sanitization container, a separate precoolingcontainer, and a modified atmosphere pallet (MAP) application system areintegrated into an overall system and process.

FIG. 28 is a diagram illustrating an embodiment of the invention inwhich a combined sanitization and precooling container and a modifiedatmosphere pallet (MAP) application system are integrated into anoverall system and process.

FIG. 29 is a diagram illustrating an embodiment of the invention inwhich a combined sanitization and precooling container and a modifiedatmosphere pallet (MAP) application system are integrated into anoverall system and process, using cross-docking sanitization andcooling, for palletized product harvested from a field.

FIG. 30 is a diagram illustrating an embodiment of the invention inwhich a plurality of combined sanitization and precooling containers anda modified atmosphere pallet (MAP) application system are integratedinto an overall system and process, using cross-docking sanitization andprecooling, along with staging and robot carriers, for palletizedproduct harvested from a field.

FIG. 31 is a diagram illustrating an embodiment of the invention inwhich a plurality of combined sanitization and precooling containers anda modified atmosphere pallet (MAP) application system are integratedinto an overall system and process, using cross-docking sanitization andprecooling, along with staging and robot carriers, for mixed loadpalletized product harvested from a field (or multiple productionsources).

FIG. 32 is a diagram illustrating an embodiment of a precooling systemof the invention using a container (or a semi-trailer) in which at leastone sensor and a programmable controller are included with the system.

FIG. 33A is a diagram illustrating a top view of an embodiment of acombined precooling and treatment unit or container of the inventionthat allows for clipping on the refrigeration equipment onto the side(s)of the unit or container.

FIG. 33B is a diagram illustrating a side or end view of the containerof FIG. 33A.

FIG. 34A is a diagram illustrating a top view of another embodiment of acombined precooling and treatment unit or container of the inventionthat allows for attaching the refrigeration equipment onto the side(s)of the unit or container with the inclusion of a trailer to hold therefrigeration equipment.

FIG. 34B is a diagram illustrating a side or end view of the containerof FIG. 34A.

FIG. 35A is a diagram illustrating a top view of another embodiment of acombined precooling and treatment unit or container of the inventionthat allows for clipping on the refrigeration equipment onto both sidesof the unit or container.

FIG. 35B is a diagram illustrating a side or end view of the containerof FIG. 35A.

FIG. 36A is a diagram illustrating a top view of an embodiment of acombined precooling and treatment unit or container of the invention inwhich a track system for moving the refrigeration equipment into and outof the unit or container is included with the system.

FIG. 36B is a diagram illustrating a side or end view of the containerof FIG. 36A.

FIG. 37A is a diagram illustrating a top view of an alternativeembodiment of a precooling system of the invention that allows for acooling plenum and refrigeration components to be built into a singleunit.

FIG. 37B is a diagram illustrating a side or end view of the precoolingsystem of FIG. 37A.

FIG. 38 is a flowchart of an embodiment of the inventive process using amobile container with a greenhouse growing facility for cooling andsanitizing perishable product.

FIG. 39 is a diagram illustrating an embodiment of the invention inwhich a plurality of combined sanitization and precooling containers areintegrated into an overall system and process, using cross-dockingsanitization and precooling, for palletized product harvested from agreenhouse operation.

FIG. 40 is a flowchart of another embodiment of the inventive processusing a mobile container with a greenhouse growing facility for coolingand sanitizing perishable product.

FIG. 41 is a diagram illustrating another embodiment of the invention inwhich a plurality of combined sanitization and precooling containers areintegrated into an overall system and process, using cross-dockingsanitization and precooling, for palletized product harvested from agreenhouse operation.

FIG. 42 is a diagram illustrating an embodiment of the invention inwhich a combined sanitization and precooling container comprises apass-thru system for palletized product harvested from a greenhouseoperation.

FIG. 43 is a diagram illustrating an embodiment of the invention inwhich a combined sanitization and precooling container comprises apass-thru system for palletized product harvested from a meat processingfacility.

FIG. 44 is a flowchart of an embodiment of the inventive process thatcomprises an integrated mobile, modular harvest to shipping operationwith harvested product.

FIG. 45 is a diagram illustrating an embodiment of the invention inwhich combined sanitization and precooling containers, a process linewithin a container, a packing line within a container, and a modifiedatmosphere pallet (MAP) application system are integrated into anoverall mobile and modular system and process, using cross-dockingsanitization, cooling, and packing for bulk packaged product harvestedfrom a field.

FIG. 46 is a flowchart of an embodiment of the inventive process thatcomprises an integrated mobile, modular harvest to shipping operationwith harvested product.

FIG. 47 is a diagram illustrating an embodiment of the invention inwhich combined sanitization and precooling containers, a process linewithin a container, and a modified atmosphere pallet (MAP) applicationsystem are integrated into an overall mobile and modular system andprocess, using cross-docking sanitization, cooling, and packing forconsumer packaged product harvested from a field.

FIG. 48 is a diagram illustrating an embodiment of the invention inwhich a combined sanitization and precooling container, aprocess/packing line within a container, and a modified atmospherepallet (MAP) application system are integrated into an overall mobileand modular system and process, using cross-docking sanitization,cooling, and packing for product harvested from a field.

FIG. 49 is a flowchart of an embodiment of the inventive process thatcomprises an integrated mobile, modular harvest to shipping operationwith harvested product.

FIG. 50 is a diagram illustrating an embodiment of the invention inwhich combined sanitization and precooling containers, a process linewithin a container, a packing line within a container, a modifiedatmosphere pallet (MAP) application system, and cold storage containersare integrated into an overall mobile and modular system and process,using cross-docking sanitization, cooling, and packing for bulk packagedproduct harvested from a field.

FIG. 51 is a diagram illustrating an embodiment of the invention inwhich a plurality of combined cooling and sanitization containers areintegrated into an overall system and process, using cross-dockingsanitization, cooling, and packing for bulk packaged product harvestedfrom a field and/or greenhouse operation.

FIG. 52 is a diagram illustrating a top view of an embodiment of amobile, modified container that includes a combined or integratedprocess and packing line for in-bound harvested product.

FIG. 53 is a diagram illustrating a top view of another embodiment of amobile, modified container that includes a combined or integratedprocess and packing line for in-bound harvested product.

FIG. 54A is a diagram illustrating an embodiment of the invention inwhich combined sanitization and precooling containers, a process linewithin a container, a packing line within a container, a modifiedatmosphere pallet (MAP) application system, and cold storage containersare integrated into an overall mobile and modular system and process,using cross-docking sanitization, cooling, and packing, along withrobotic pallet handling.

FIG. 54B is a diagram illustrating a robotic pallet according to oneembodiment of the invention.

FIG. 55 is a diagram illustrating an embodiment of the invention inwhich a plurality of combined cooling and sanitization containers areintegrated into an overall system and process, using cross-dockingsanitization, cooling, and packing, along with robotic pallets, forproduct harvested from a field and/or greenhouse operation.

FIG. 56 is a diagram illustrating an embodiment of the invention of anoverall mobile, modular system with a covered-cooled interconnectedcross-dock for a sanitization, cooling, and shipping operation fromharvest into finished or bulk packages.

FIG. 57 is a diagram illustrating an embodiment of the invention inwhich a combined cooling and sanitization container(s) is integratedinto an overall system and process, using cross-docking sanitization andcooling with optional product handling, using modified refrigerated orinsulated trailers, shipping containers, and/or prefabricated, modularmovable units or containers.

FIGS. 58A and 58B are diagrams illustrating the various functionaloperations and systems for performing the cooling, sanitization, and/orfunctional treatment steps according to an embodiment of the invention.

FIG. 59 is a diagram illustrating an embodiment of a system having afunctional treatment and delivery platform for providing sanitizationand/or functional treatment substances to a perishable product afterharvesting.

FIG. 60 is a diagram illustrating an embodiment of the invention inwhich a plurality of combined cooling and sanitization containers areoptionally integrated into an overall system and process, usingcross-docking sanitization, cooling, and optional packing for bulkpackaged product harvested from a field and/or greenhouse operation.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure relates to an improved system and method using amodified container, refrigerated semi-trailer, or prefabricatedcontainer (or trailer) for application of sanitizing substances to thesurface of a perishable product and also for efficiently precoolingperishable product. The present disclosure further relates to animproved system and method of using a modified container and/orsemi-trailer and/or prefabricated container (or trailer) for processingand/or packaging a product before and/or after applying sanitizingsubstances to a perishable product and/or precooling perishable product.According to embodiments of the invention, the various disclosed systemsand methods can cool, treat, process, and/or package products thatinclude one or more of (i) pre-packed product after harvesting, (ii)bulk packed product into a harvest container to supply to a packingline, and (iii) product packed into a partial container that needsadditional handling/processing steps to complete the packing of theharvested product.

Typical produce cooling and distribution facilities operate seasonallyduring the climate driven growing and harvest seasons. These expensivefacilities are typically designed for produce volumes that anticipate anormal rate of product arriving for processing. The time from harvest tobeing cooled to the intended storage temperature is perhaps the mostimportant postharvest process factor for quality and shelf life. Inreality, produce arrives in surges during the day and the season in away that cooling, and distribution facilities are generally not able tomaintain the intended cooling standards. Under actual commercial coolingconditions, it is extremely difficult to maintain a completely constantair temperature. Warm fruit is constantly being brought into the coolerduring operation, and forklifts must pass in and out of the cooler. Thiscan result in the cooling facility temperature increasing or warmingduring the day, which slows the cooling process and even prevents thecooling systems from delivering the produce to its intended temperature.Because of the capacity challenges, regular cleaning and sanitation ofthe refrigeration and air flow systems is neglected, resulting in airthat may contain mold spores and other spoilage organisms. Onceairborne, these mold spores and/or organisms can cross-contaminate theproduce coming through the facility, resulting in a product with moldand decay during the supply chain to the consumer. Thereafter, theentire impacted facility is left to remain underutilized or idle untilthe growing season returns.

Additionally, greenhouse facilities and/or packing house facilities thatare designed to pack perishable product typically provide no precoolingcapability. The perishable product is then not cooled untiltransportation and delivery to a cold storage facility which could bemiles, hours or days away. Such locations could take advantage ofeffective precooling where the equipment required can be easily placedand put into operation to support harvest operations.

For example, current precooling systems for perishable produce are all“fixed in place” installations within cold-room warehouses (see, e.g.,FIG. 13). Air within these warehouses that is cooled via a centralcooling system is forced through pallets of product that have beentransported from a field to cool the product. The central cooling systemof these warehouses is thus tasked to remove the field heat that comesout of the pallets of warm product and mixes with the warehouse air. Thecold-room warehouses are not frequently sanitized to maintain lowmicro-organism presence as would be likely present in a perishableprocessing facility. Accordingly, spores of mold and other spoilageorganisms brought in from the fields on some of the products aredistributed in the cold warehouse air, thereby exposing and spreadingthese organisms to other products during the cooling of the product bythe central cooling system.

As described above, current precooling systems in warehouses do notprovide any type of sanitization to product that has been packed in thefield. Their purpose is to cool the product to the target temperaturefor shipment. So, sanitization is a missing step in the process toproduce and market perishable product with exceptional quality, shelflife and safety. It is a specific intention of this invention to providea system, method and apparatus where the product is isolated from thewarehouse and operating personnel, and the product can receive atreatment of substances that will reduce or eliminate mold andpathogenic or spoilage organisms. These substances typically haverestrictions based upon personnel safety or equipment based on materialof construction issues. This dedicated space for providing treatment tothe product, in which the product is isolated from the warehouse andoperating personnel, can be designed to remedy those limitations orrestrictions.

Depending on the physical configuration and weight packed onto a palletfor shipping and the starting temperature of the product or produceafter being harvested directly from the field, which can range fromabout 55° F. to about +95° F. (i.e., an average starting temperature ofabout 75° F.), about 25,000-45,000 Btu's of cooling is required to coolan individual pallet of product to the intended temperature for storageand shipment, which is generally around 34° F. for commodities, like,e.g., berries. For example, produce or fruit products such as berrieshave a specific heat (C_(p)) of about 0.95 Btu/lbF. If an average palletweights 1,000 lbs., then the cooling process (Q=mC_(p)dT) must removeabout 34,200 Btu's [0.95 (Btu/lbF)×1,000(lbs)×31(F)=34,200 Btu] from thepallet of product. Some additional cooling (Btu's) is typically includedin the facility capacity to account for (i) heat of any cooling fans and(ii) condensation of water from the air on the refrigeration surface.Assuming that the additional cooling requirements are about 1,100 Btu's,a total “Q” for a cooling requirement equals to about 35,300 Btu's, forone pallet. It is, thus, intended that the modified container orrefrigerated semi-trailer of the invention will provide about25,000-45,000 Btu's per pallet of cooling capacity, dependent on thephysical weight present. The intended cooling time then determines howmany Btu's per pallet per hour are required.

Moreover, for cold air to remove the amount of heat discussed above(i.e., about 35,300 Btu's), a similar calculation can be used todetermine the amount of air required. In particular, cold air has aspecific heat (C_(r)) of about 0.2403 Btu/lbF and a density of about0.075 lb/cu.ft., with a temperature of about 32° F. Using the total “Q”for a cooling requirement of 35,300 Btu's, the variable of “m” (i.e.,the amount of air in cu.ft.) can be determined in the above-discussedequation (Q=mC_(p)dT). This results in an “m” of about 54,400 cu.ft. of32° F. air that is required to remove the heat. If applied over 60minutes, this would translate to about 907 cubic feet per minute (cfm)per pallet (or about 450 cfm of airflow per pallet cooled over atwo-hour time frame). Currently, intermodal containers and semi-trailersonly produce a total of about 20-35,000 Btu's per hour, distributed toall of the pallets present. This is because their primary purpose is tomaintain product temperature during transportation. Air flow must,therefore, also be proportionally increased with the modifications tothe container or refrigerated semi-trailer of the invention to achievethe cooling in a rapid fashion. It is, thus, intended that air flow withthe modifications to the container or refrigerated semi-trailer of theinvention will provide about 500 to 3,000 cfm per pallet depending onthe weight of the product and amount of static pressure or resistance toair flow caused by the boxes, containers, size and density of theproduct or produce. This will enable effective recirculation of thesanitizing substances across the pallets of perishable product. Therefrigeration to cool the product would be sized and controlleddepending on the desired cooling time.

It should be noted that fruits and vegetables all have unique commercialcooling requirements and specifications (see, e.g., FIG. 22). For thatmatter, the amount of Btu's/hr and cfm per pallet required could bedifferent. Banana pallets, for example, are twice the weight of berriesat over 2,000 lbs. In addition, bananas would be cooled from a tropicaltemperature of about 90° F. to about 58° F. This process to reduce thetemperature by 32° F. with twice the fruit amount would require twicethe cooling Btu's and air flow for an intended cooling time. Fruit andvegetable items have a preferred cooled temperature where they have areduced rate of respiration for shipping but don't incur chill damage(see, e.g., FIGS. 20 and 21). Along with different pack weights,packaging, and as-harvested starting product temperature, it should beexpected that the cooling and air flow capacity requirements would beappropriately designed to achieve the target cooling time through themodifications of the mobile containers. It is important to note thatduring this cooling time, the sanitization treatment can be applied toprovide a substantial exposure, contact, or dwell time. Longer exposureand dwell times enable use of lower active levels of the sanitizersubstances, which can be advantageous to avoiding damage to theperishable product, packaging, as well as the materials of construction.

Additionally, climacteric fruit that is ripening, such as bananas,avocadoes, and tomatoes, produce heat during the ripening process (i.e.,heat of reaction during ripening process of converting starch to sugar).The cooling and air flow that is needed to prevent fruit from heating upduring ripening is substantially more than that required for maintainingthe temperature of a green (or un-ripened) fruit at normal respiration.Accordingly, the cooling (Btu capacity) and air flow required forpreventing fruit from heating up during ripening is analogous to theprecooling situation described above. Thus, the expanded cooling and airflow capability described above (i.e., a cooling capacity of about25,000-45,000 Btu's per hour per pallet, and an air flow of about 500 to1,000 cfm per pallet) reasonably matches with the requirements to removethe heat of ripening from climacteric perishables, such as bananas,avocadoes and tomatoes. Moreover, in use, the modified container,semi-trailer, or prefabricated container (or trailer) is a closedsystem, which allows for the modified container, semi-trailer, orprefabricated container (or trailer) to (i) contain substances for asanitizing treatment, as well as ethylene, which is generally used toinitiate or accelerate ripening and/or (ii) control the humidity and/ormoisture vapor pressure differential between the environment and theproduct. These conditioning and/or ripening features can be importantfor other items such as melons, kiwi, and stone fruit which are oftenharvested less than fully ripe and whose quality, condition, andorganoleptic properties can be significantly improved by the system andmethods including, e.g., exposure to controlled amounts of ethylene.

In view of the foregoing, the modified container, refrigeratedsemi-trailer, or prefabricated container (or trailer) of the inventionis intended to provide about 25,000-45,000 Btu's per hour per pallet ofcooling capacity. Additionally, the modified or prefabricated containeror refrigerated semi-trailer of the invention is intended to provide anair flow of about 500 to 3,000 cfm per pallet. Moreover, the mobile orprefabricated container or semi-trailer described herein providesindependent and incremental cooling to the operation. The mobile orprefabricated container can augment or replace the air flow plenums orprecooling systems currently located within the cold storage facility,freeing up space for produce storage during production peaks. As anindependent system, the mobile or prefabricated container is notimpacted by volume surges that can occur. By utilizing the additionalcooling systems, the user is able to have excess cooling capacity toproperly manage all surges. Thereafter, the user is able to get greaterutilization of these assets by moving them for use at the next seasonallocation. The use of the mobile container or prefabricated container (ortrailer) enables the user to consider facilities for cooling, storageand distribution that before could not have been considered due to theirlack of sufficient size and capacity. Often the construction of largecold storage warehouse involves substantial expense and time due tolocal regulations and the permitting process. The mobile orprefabricated container is flexible to be able to operate while on thechassis, placed on a frame to match the desired operational height, oralso placed on the ground or concrete floor. Such facilities might becalled packing houses where there is typically no precooling. The mobileor prefabricated container is also equipped with a sanitizing additionsystem to reduce the mold and spoilage organism counts on the surface ofthe produce. Important elements of the container design enable thesystem to be cleaned of the debris inherent with a field packed product.The mobile or prefabricated container is able to be cleaned andsanitized daily or as needed after use, so as to eliminate the currentcross-contamination of mold spores and/or spoilage organisms that occurswith the current cooling process within the warehouse.

Most important of all is that the improved system is able to provide acurrently missed step of sanitization to reduce, control, or eliminatemold, pathogenic, or spoilage organisms. Combining this with precoolingand the prescribed product handling methods insures the perishableproduct is not cross-contaminated or re-contaminated within thewarehouse.

The overall net result is improved quality from harvest to cool time,intended produce temperature, and reduced surface mold and/or spoilageorganisms. The cooling operation has cooling assets that operate morecost efficiently (i.e., asset cost/carton processed), as well asincreased storage space to manage surges in production.

In addition, a mobile or prefabricated container that is capable ofproviding pre-cooling and/or sanitization treatments is an idealapparatus, method, and system to support, for example, the urban orglobal smart greenhouse industry. This industry is growing throughoutthe world due to the need to bring food production closer to the urbanpopulation centers, to enable throughout the year growing independent ofseasonal weather, and to reduce the costs and lost freshness of extendedtransportation and logistics. Commercial greenhouses are high-techstructures, which provide stable, highly controlled environments for thecultivation of plants, such as, e.g., flowers, vegetables, and fruits tocommercial growers. Environmental factors such as, e.g., temperature,light exposure, irrigation, fertilization, humidity, and ventilation canbe precisely controlled by growers in smart greenhouses for the optimalgrowth of crops. Commercial smart greenhouses enable the cultivation ofplants in large volumes for commercial growers. These greenhousesmaintain mid-to-high temperatures (often between 45° F. and 100° F.,depending on plants being cultivated or the season of the year) usingglass or plastic materials to enable the transmission of visible andnear-visible ultraviolet (UV) and/or infrared radiation (IR). Anotherapproach to indoor plant growing involves indoor and vertical farmsusing repurposed buildings, warehouses, or vacant properties. In allcases, a solution is needed for proper post-harvest processing of theperishables. Thus, by providing a mobile container with supportingrefrigeration, which can be located at the receiving and shipping dockof these types of facilities, minimal facility modifications would beneeded. Importantly, as a programmable system, the necessary precoolingconditions and sanitization materials used can be prescribed for theoperation. The system can be simply connected to the operation and willfunction to provide state of the art cooling, sanitization andfunctional treatments for the perishables to enhance their quality,safety, and provide extended shelf life for consumers.

In a similar fashion, meat and other proteins are being produced atsmaller, more local facilities instead of conventional large, regionalpacking houses. Accordingly, the above-discussed mobile containers withcooling and/or non-thermal or cold treatment capabilities can beutilized for these products. In particular, because the mobile containerapparatus can be located outside of the facility and not inside wherepersonnel are present, there is a broader list of materials that can beused to treat the surface of the protein products. Carriers such as,e.g., liquid nitrogen and carbon dioxide can also be used to deliverfunctional treatments and/or sanitizers to the surfaces of the products.According to one embodiment, non-thermal treatments (i.e., treatmentsnot requiring heat or heating, raising the temperature, or exposing theperishable product to higher temperatures) that can be utilized for meatand other protein products (as well as other perishable products,including, e.g., produce products and other non-meat or non-proteinproducts) include directed electrical energy, electrical pulses,ultra-sound, UV light, and/or electromagnetic treatments, whereby theyactivate substances already applied to the surface of the product,and/or are used as standalone substance treatments by impacting theelectrons and subsequently damage or destroy microorganisms or convertpesticides or other substances or undesirable chemical compounds intoharmless compounds.

Accordingly, one embodiment includes an independent apparatus forcooling a perishable product to its intended temperature using one of(i) a mobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer (or trailer), which is modified to add high capacityrefrigeration and high capacity airflow that is forced through palletsof cartons with perishable produce. During a period of cooling,sanitizing substances are recirculated with the airflow across a surfaceof the perishable product with the effect of reducing at least one of(i) pathogenic organisms or (ii) spoilage organisms that occur on thesurface of the perishable product. The one of (i) a mobile container,(ii) a semi-trailer, or (iii) a prefabricated container (or trailer) isconfigured to be relocated to a seasonal growing area or production areafor year-round utilization.

Another embodiment includes an apparatus for sanitizing a perishableproduct in which sanitizing substances are recirculated within air thatflows across a surface of the perishable product with the effect ofreducing at least one of (i) pathogenic organisms or (ii) spoilageorganisms that occur on the surface of the perishable product.

Another embodiment includes one or more methods for treating aperishable product and/or using the various apparatus described herein.

FIG. 1 is a flowchart of a typical or conventional berry coolingprocess. This process uses tarps for vacuum plenums within a coldstorage facility. A 10 pallet plenum requires 200 square feet ofrefrigerated floor space that is adjacent to a wall with a plenum fan(for setting up tarps for cooling), plus access for pallet movement. Thefacility creates and recirculates 32° F. air throughout. The plenum fansucks this air through cartons of berries staged at the plenums. Coolingcontinues until the berries reach the intended temperature of 32-34° F.Berries closest to the suction fans cool faster. The cold air beingrecirculated in the facility may contain mold spores or other spoilageorganisms. Heat from the suction fans and removed from the fruit ismixed in the facility air. If that heat exceeds the capacity of thefacility's cooling units, the air will warm and then this warmer airwill result in slower cooling and higher finished berry temperature. Thegreater than two (2) hours to cool ten (10) pallets (“forced aircooling”), along with the pallet movements and tarp plenum setup,results in a total time until delivery to and staging for a MAP(modified atmosphere pallet) of greater than 155 minutes. At this rate,about 40 pallets can be processed within a 10-hour day per plenum.Limited storage space in the cold storage facility often requires theuse of racks to store product vertically. This design, which may benecessary for production storage during surges, may be less efficientfor pallet movements during peak operating times of the day. Forexample, when pallets are all placed on the floor of the facility, theycan be moved by forklifts one or two at a time and quickly. However,when loading pallets into vertical racks, they must be handled one at atime and very carefully to position the pallets correctly on the rack.This is the same for removing the pallets and placing them in theshipping area. Racks, however, may be necessary when additional coldstorage space is needed in the facility, but they have an impact onoperations. Additionally, forklift drivers also require more skill forplacement of the pallets onto the vertical racks. FIG. 2 is a flowchartof an embodiment of the inventive process using a mobile containerdesigned to cool the berries to an intended temperature in one (1) hourand also able to provide a sanitizing treatment during that time period.Following the cooling and treatment process, the pallets of produce orperishable products are moved into a cold storage facility to a MAPstation for final processing. With sufficient cooling capacity applied,this inventive process for a 9-12 pallet container design occurs with 60minutes of cooling (“forced air cooling and treatment”) and translatesto 80 pallets processed within a 10-hour operation. At a 2× capacity,along with mobility to cool produce or perishable products at otherseasonal harvest or production locations, this system provides a costeffective cooling capability. With this, the process frees up about 400square feet of space for storage within the cold storage facility. If alesser amount of cooling capacity is applied, a longer cooling andtreatment time will occur, but this will still augment or replace someof the capacity within the cooling facility.

FIGS. 3, 4A, and 4B are diagrams illustrating an embodiment of aprecooling system described by the flowchart in FIG. 2. This examplereflects using a 40′ high cube reefer container (100), but couldalternatively be a 53′ semi-trailer. This is a modification to aconventional refrigerated container and/or semi-trailers, which are ableto be moved to the various seasonal locations where needed. (Forexample, FIGS. 5 and 6 illustrate information about conventionalintermodal refrigerated containers and/or semi-trailers that can bemodified according to the embodiments described herein.) In themodification, fans (122) and cooling coils (124) are placed along theside of one wall to create an air flow plenum (120) to force air(horizontal and/or vertical arrows in FIGS. 4A and 4B) through theadjacent pallets (150). By contrast, standard containers orsemi-trailers that include cooling capacity often use air deliveryequipment located in the front of the unit. Thus, the air must travel toextreme distances through a small channel or plenum to reach and cooleach pallet. Accordingly, pallets farthest away from the air deliveryequipment receive less air flow and will be slower to cool and, thus,delay the conclusion of the cooling process. (See, e.g., FIGS. 7 and 8,which illustrate the air flow patterns for this conventional type ofequipment.) However, the modified container or semi-trailer of theinvention is modified to add supplemental air flow and cooling capacitythat is adjacent to each pallet. Accordingly, the air flow is directedhorizontally through each of the pallets (see, e.g., FIGS. 4A and 4B).This enhanced, direct air delivery approach ensures that each palletreceives the same increased capacity of air flow and then cools fasterand more uniformly. In this manner, cooling can occur, and a gaseous,very small micron substance or vaporized sanitizer can be recirculatedthrough the pallet and across the fruit to provide a “dry washing” step.For example, as shown in FIG. 4B, a treatment sprayer (140) can beincluded to provide this gaseous, very small micron substance, orvaporized sanitizer to the air flow plenum (120) to be recirculatedthrough the pallets (150). Given the 60-minute or longer time durationfor cooling, this exposure time enables use of lower concentrations ofactive sanitizer material to achieve the beneficial effect of reducingand/or neutralizing any spoilage organisms, while not damaging thefruit, vegetable, or other perishable. In particular, sanitizer efficacyis a function of concentration/strength of action and exposure time.Moreover, certain high concentrations of sanitizers and/or strongsanitizers could damage the product. Certain amounts or types ofsanitizers could also damage the materials of construction of thecontainer and/or the refrigeration equipment. Accordingly, the systemallows for (i) using a lower or a milder level of sanitizer for a longerperiod of time during cooling, which enables an effective treatment,without the damage that is generally associated with short time/highconcentration exposure, (ii) a controlled higher level of sanitizer witha carefully managed shorter period of contact time of sanitizer, and/or(iii) a short controlled exposure prior to deactivation during coolingas may be required to enable an effective treatment, without the damagethat is generally associated with short time/high concentrationexposure. This could not occur in conjunction with any other commercialcooling process that uses high concentrations of sanitizing materialseven in short time bursts. For example, current cooling systems usingtarp plenums within an open atmosphere environment with operatingpersonnel are not capable of this process. According to anotherembodiment of the invention, special coatings can be applied to thesurface of the interior of the container or semi-trailer and/orconstruction materials such as, e.g., stainless steel are used that areresistant to damage from strong sanitizers can be used to allow forthese types of sanitizing treatments for certain types of products.

While not required for the process, a shuttle conveyor system (160) thatmoves pallets (150) in and then back out of the container (100) offerssite flexibility to eliminate forklifts driving into the container(100). In addition, drop off and pickup on the exterior conveyor (160)enables faster loading and discharge.

FIGS. 9, 10A, and 10B illustrate an alternative embodiment of aprecooling system of the invention in which the 40′ container (200) (or,alternatively, a 53′ semi-trailer) are modified to create “pop out”sides (220) that can provide sufficiently wide air supply plenum toincrease the capacity of the unit to at least 18 to 24 pallets (250).One or more cooling systems (225) would be mounted above the container(200), and the ceiling would be modified (see, e.g., baffles (290)) toenable the air recirculation (horizontal and/or vertical arrows)depicted in FIGS. 10A and 10B. The one or more cooling systems (225)include fans (222) and cooling coils (224) to provide the necessarycooling capacity to the container (200). Under certain conditions, astandard width container (200) or a semi-trailer does not provide enoughspace in the plenums, nor return air column to effectively distributethe necessary air flow to cool the fruit in the time needed.Accordingly, the “pop-out” sides (220) provide this necessary air flowfor cooling the fruit in the time needed. According to one embodiment,the “pop-out” sides (220) can “slide in” and lock for transport and“slide out” and lock during operation. According to this embodiment,greater capacity and uniformity for cooling, sanitizing, and/or ripeningis possible, as well as a higher volume of more efficient air flow.Additionally, according to this embodiment, a treatment sprayer (240)can be included to provide a gaseous or vaporized sanitizer to the“pop-out” sides (220) or air flow plenum to be recirculated through thepallets (250).

Again, while not required for the process, a shuttle conveyor system(260) that moves pallets (250) in and then back out of the container(200) offers site flexibility to eliminate forklifts driving into thecontainer (200). In addition, drop off and pickup on the exteriorconveyor (260) enables faster loading and discharge.

FIGS. 11A and 11B illustrate an alternative embodiment of a precoolingsystem of the invention in which the refrigeration units (320) and/orpressure air equipment (320) are clipped onto the sides (310) of thecontainer (300). The refrigeration units (320) and/or pressure airequipment (320) includes, for example, fans (322) and cooling coils(324) to provide the necessary cooling capacity to the container (300).Openings (315) in the sidewalls (310) (see, e.g., FIG. 11C) enable thepallets (350) to be placed at the side of the container (300). Air isforced through the pallets (350) of cartons to the center open column(see horizontal and/or vertical arrows in FIGS. 11A and 11B). The airreturns up and over the pallets (350) back to the refrigeration units(320). For relocation to the next seasonal harvest area, therefrigeration units (320) are un-clipped, stored inside the container(300), and then moved to the next site for reassembly. Additionally,according to this embodiment, a treatment system or spray system (340)can be included to provide a gaseous, suspended ultra to small micronsubstance treatment or vaporized sanitizer to be drawn through theproducts by the fans of the refrigeration units (320) to be recirculatedthrough the pallets (350).

Again, while not required for the process, a shuttle conveyor system(360) that moves pallets (350) in and then back out of the container(300) offers site flexibility to eliminate forklifts driving into thecontainer (300). In addition, drop off and pickup on the exteriorconveyor (360) enables faster loading and discharge.

FIG. 11C illustrates the modifications to the sidewalls (310) of thecontainer (300) of FIGS. 11A and 11B to cut out sections of theinsulated sidewall(s) (310) to provide openings (315) to enable air toflow from the refrigeration unit (320) to the pallets (350) ofperishable product and then return over the top of the pallet (350) andback to the refrigeration unit (320). The cut-out sections or openings(315) can be further modified with a vent cover design to open andclose, and adjust the direction and amount of air flow to the pallets(350).

FIG. 12A illustrates a flowchart of an embodiment of the inventiveprocess in which a modified container is used for sanitizing alone, andnot cooling. This process would use one of the designs for the modifiedcontainers or semi-trailers described above. As shown, the sanitizationcan occur before cooling. The sanitization treatment within thecontainer could also occur after cooling.

FIG. 12B illustrates a flowchart of an embodiment of the inventiveprocess in which a sanitizing treatment occurs before cooling and then asecond sanitizing treatment occurs within the MAP (modified atmospherepallet) process. FIG. 12C illustrates a flowchart of an embodiment ofthe inventive process having a combination of multiple sanitizingtreatments, with the first sanitizing treatment occurring within acooling step in a modified container (as described above). According tothis embodiment, a cooling step (“forced air cooling”) in a modifiedcontainer occurs for one-hour (60-minutes), which is followed by or incombination with a MAP process with sanitizer treatment. Because of the60-minute residence time for cooling and receiving the sanitizingtreatment, this combination process that includes a MAP sanitizer stepshould yield the best overall results. In particular, the 60-minutetreatment during cooling enables a milder but longer exposure time forthe sanitizer application. Additionally, the MAP sanitizer treatmentadds a sanitizer that could be synergistic or that can impact anyresidual spoilage or pathogenic organisms present. For example, somesanitizing materials, such as essential oils, can provide sanitizingeffects and impact over the days that it takes to deliver the sealedpallet to a customer. As further shown in FIG. 12C, this overall processis achieved with an 85-minute process time.

FIG. 13 illustrates a typical or conventional cooling, storage, andshipping facility (400) for perishable produce or product. Note that thespace (450) allocated for pre-cooling and pallet movements associatedtherewith requires that about 40% of the facility be available forcooling in a refrigerated space. Accordingly, a large amount of thefacility space has to be reserved for pre-cooling product in anefficient manner.

FIG. 14 illustrates an embodiment of the invention using mobilecontainers (550) to apply the sanitizing treatment before cooling andstorage in the warehouse (500). Note that three containers (550) easilymatch with ten tarp plenums that require two hours to cool product. Inthe event of peak production requirements, the facility can add moremobile containers (550) staged adjacent the receiving dock (520).

FIG. 15A illustrates an embodiment of the invention using modifiedcontainers (650) to cool and to apply the sanitizing treatment beforestorage in the warehouse (600), eliminating the warehouse's current tarpcooling systems. Note that five containers (650) cooling at least ninepallets in one hour are able to approximately replace the ten tarpplenums that require two hours to cool the same amount of product. Thismodification opens up about 40% of the warehouse (600) for additionalstorage. This enables avoiding the use of racking, which slows palletmovement and turnover in the warehouse (600). The perishable product hasbeen cooled as intended and received a sanitizing treatment. Thewarehouse storage temperature will not be impacted by production surges.In the event of peak production requirements, the facility can add moremobile containers (650) staged adjacent to the receiving dock (620). Ifthe containers (650), modified to contain at least 40 pallets (see,e.g., FIGS. 10A, 10B, 11A, and 11B), were used, then the number ofcontainers (650) could be reduced, or the capacity of the warehouseoperation could be significantly increased.

FIG. 15B illustrates an embodiment for two separate system designs.According to one embodiment, there are five exterior precooling andtreatment systems (650) and five pass-thru precooling and treatmentsystems (660) that are located within the warehouse (600). In anotherembodiment, the exterior systems (650) are used for precooling ortreatment, and then the pass-thru systems (660) are used for the othercomplementary step, e.g., treatment or precooling. This sequential ortandem use of the mobile systems would allow for separation of thecooling and sanitizing treatments for situations where the sanitizerscause undesirable amounts of freezing on the refrigeration coils and/orcorrosion on the coils or other sensitive components within thecontainer.

As discussed above, in the embodiments of FIGS. 10A, 10B, 11A and 11B, ashuttle conveyor is illustrated for the purpose of easily moving palletsinto and out of the modified container. This shuttle conveyor could alsobe included with the embodiments of FIGS. 15A and 15B (as well as FIGS.16A-16C, as described below), as this enables pallet movement andpositioning without the need and time expense to physically drive thepallets into and out of the container. The shuttle conveyor can beeither an “in-and-out” design from one end, or a pass-thru design wherethe pallets are loaded at one end and removed from the other end. Thisdesign has advantages from other more continuous conveying and coolingsystems in use today that have complicated materials and components forcontinuously moving and sealing plenums to pallets. Those componentslead to expensive construction and maintenance expenses and have somelimitations in the use of sanitizing materials for product treatment.This design is simpler and less costly to construct and maintain.Additionally, a single treatment and/or cooling zone can be utilized foreither one continuous treatment or stages/cycles of treatment that canaccomplish different functional benefits.

FIG. 16A illustrates an embodiment of the invention using modifiedcontainers (750) receiving the warm product on the receiving dock (720),cooling and sanitizing the product, and then the product is removed fromwithin the warehouse (700). By keeping the warehouse (700) closed duringthe receiving steps, the warehouse (700) is able to control itstemperature more accurately and efficiently. The receiving door is notopened for forklifts to enter and leave, thus eliminating this intrusionof warm outside air and the escape of cold air. Storage space in thecold warehouse (700) is still increased over the current base design.

FIG. 16B illustrates an embodiment of the invention in which a MAPapplication system (760) is connected via a set of conveyors (780) tothe modified containers (750) to complete the preparation of the cooledand ready for shipment pallet (see, e.g., FIG. 19). Through thisembodiment and set-up, a pallet handling step from the mobile cooler tothe MAP system is eliminated. This further reduces the storage spacerequired for pallets to be staged during the processing steps. Palletsmove to the MAP process immediately after cooling and can then be loadeddirectly to transportation trucks in a semi-automatic process.

FIG. 16C illustrates an embodiment of the invention in which acombination of exterior systems (790) and pass-thru systems (750) areused for tandem cooling and sanitizing treatment, and then connected toan MAP system (760). By coupling mobile systems (750 and 790), conveyors(780), and an MAP process (760) in this way, maximum cold storage spaceis provided, while eliminating an operational handling step requiring aforklift and labor, and minimizing any contamination that could occurwithin the cold warehouse (700). Moreover, the sealed MAP pallet isready for shipment or short term cold storage.

With the cooling and handling steps minimized in the use of the mobilecontainers and conveyors, it can be conceived that the cooling andtreatment operation can be set up at simple packing houses and enablethe product to completely by-pass the need to go to the coolingwarehouses, saving important process time and expense.

FIG. 17 illustrates a flow chart of an embodiment of the inventionprocess using the mobile container with exceptional refrigeration andair flow to add a conditioning or ripeness management substance toimprove the organoleptic properties of the perishable product.Importantly, the refrigeration and air flow capacity will exceed that ofthe standard container, enabling it to control the heat generated by theripening of climacteric perishable items.

FIG. 18 illustrates an embodiment of a modified container according tothe invention in which a portion of the floor (800) of the containerincludes tee rails (810), as well as container floor drains (820) andsupplemental drains (850). The supplemental drains (850) are includedfor removal of debris remaining in the container from field packedproduct. These drains (850) are able to be sealed, but also opened up toaid in the cleaning of pieces of dirt and wood. As discussed above,these supplemental drains (850) are provided in addition to thecontainer floor drains (820) that are included with the system (seealso, e.g., container drains (180, 280, 380) provided with thecontainers (100, 200, and 300) of the embodiments illustrated in FIGS.4A, 4B, 10A, 10B, 11A and 11B).

FIG. 23 is a flowchart of a yet another typical or conventional berrycooling process. In this process, a perishable product (e.g., berries)is packed at the harvesting field and then must be moved or transportedto a warehouse (which generally takes about two (2) to four (4) hours).The pallets of product are usually held before cooling, until a forkliftcan move the pallets to the area of cooling. As in the process of FIG.1, this process uses tarps for vacuum plenums within a cold storagefacility. The plenum fan sucks air through cartons or pallets of productstaged at the plenums (“forced air cooling”). Cooling continues untilthe product reaches the intended temperature (usually 32-34° F.). Thetwo (2) hours to four (4) hours generally required to cool the palletsof product (“forced air cooling”), along with the pallet movements andtarp plenum setup, results in a total time until delivery to and stagingfor a MAP (modified atmosphere pallet) of 2.5 to 4.5 hours. As furthershown in FIG. 23, the time between harvesting the product to the timethe product even begins the cooling process via “forced air cooling” isabout 3 to 7 hours. Moreover, as shown in FIG. 23, the overall “harvestto cool time” is about 5 to 11 hours.

FIG. 24 is a flowchart of an embodiment of the inventive process using amobile container designed to cool the berries to an intended temperaturewithin one (1) hour to two (2) hours, while also being able to provide asanitizing treatment during that time period. In this process, aperishable product (e.g., berries) is packed at the harvesting field andthen must be moved or transported to the mobile container that ispositioned near the harvesting field (which generally takes less thanone (1) hour). The pallets of product are then moved into the mobilecontainer by, for example, a forklift. As in the process of FIG. 2, thepallets are cooled and sanitized/treated within the mobile container(“forced air cooling/sanitize”). Cooling continues until the productreaches the intended temperature (usually 32-34° F.), which generallytakes around one (1) hour to two (2) hours. The one (1) hour to two (2)hours generally required to cool the pallets of product (“forced aircooling/sanitize”), along with the pallet movements, results in a totaltime until delivery to and staging for a MAP (modified atmospherepallet) of 1.5 to 2.5 hours. As further shown in FIG. 24, the timebetween harvesting the product to the time the product begins thecooling process via “forced air cooling” is a little over one (1) hour,which is significantly less than the 3 to 7 hours for the time betweenharvesting the product to the time the product begins the coolingprocess of the typical cooling process shown in FIG. 23. Moreover, asshown in FIG. 24, the overall “harvest to cool time” is about 2 to 3hours, which, again, is much faster than the 5 to 11 hours of thetypical cooling process shown in FIG. 23.

Further benefits of the inventive system and process are illustrated inFIGS. 25 and 26. For example, FIGS. 25 and 26 illustrate the differencesin product respiration with respect to the “harvest to cool time” of theprecooling process of the inventive system compared to the typicalcooling process shown in, for example, FIG. 23. In particular, as shownin FIG. 25, the significant excess respiration of the product (alsoknown as, e.g., “product aging”) as a result of delayed precooling,which occurs with the typical cooling process shown in, for example,FIG. 23, results in less shelf life for the product (i.e., each hour ofdelay in cooling results in about 0.5 days of shelf life). Thus, asshown in FIG. 25, the precooling process of the inventive systemprovides a product that is at least 20% fresher or has 2.5 additionaldays of shelf life. Moreover, as shown in FIG. 26, depending on the timeof day for the harvest, even more shelf life is preserved using theprecooling process of the inventive system, as compared to the typicalcooling process shown in, for example, FIG. 23, due to at least thesignificant decreases in the “harvest to cool time” of the precoolingprocess of the inventive system. As further shown in FIG. 26, theprecooling process of the inventive system further provides fordecreases in mold spores and/or spoilage organisms present on theproduct, as compared to the typical cooling process shown in, forexample, FIG. 23.

FIG. 27 illustrates an embodiment of an overall system (900) of theinvention that includes an integrated sanitization, precooling and MAPprocess. In particular, the system (900) of FIG. 27 includes a separatesanitization container or unit (910), a separate precooling container orunit (920), and an automated, modified atmosphere pallet (MAP)application system (930). In this embodiment, pallets of perishableproduct are first placed within the separate sanitization container(910) for treatment with a sanitizer to reduce spoilage or pathogenicorganisms that may be present on the surface of the product. Thereafter,the treated pallets of perishable product are moved or transported tothe separate precooling container (920) to cool the product to adesirable temperature (e.g., 32-34° F.). After cooling, the perishableproduct is moved or transported to the automated, modified atmospherepallet (MAP) application system (930) to add an MAP to the product.Although the MAP system (930) in this embodiment is automated, the MAPsystem (930) could also be semi-automatic. Once the pallets havecompleted the application in the MAP system (930), the pallets arefinally moved or transported to a final shipping semi-trailer (960) fortransportation to a storage warehouse or other location. According tothis embodiment, pallets of perishable product are moved or transportedbetween each of the separate containers or apparatus via one or moreshuttle conveyors (950).

FIG. 28 illustrates another embodiment of an overall system (900′) ofthe invention that includes an alternative, integrated sanitization,precooling and MAP process. In this embodiment, the system (900′)includes a combination sanitization and precooling container or unit(915) and an automated, modified atmosphere pallet (MAP) applicationsystem (930). According to this embodiment, pallets of perishableproduct are first placed within the combination sanitization andprecooling container (915) for treatment with a sanitizer to reducespoilage or pathogenic organisms that may be present on the surface ofthe product, while also cooling the product to a desirable temperature(e.g., 32-34° F.). After treatment and cooling, the perishable productis moved or transported to the automated, modified atmosphere pallet(MAP) application system (930) to add an MAP to the product. Althoughthe MAP system (930) in this embodiment is automated, the MAP system(930) could also be semi-automatic. Once the pallets have completed theapplication in the MAP system (930), the pallets are finally moved ortransported to a final shipping semi-trailer (960) for transportation toa storage warehouse or other location. According to this embodiment,pallets of perishable product are moved or transported between each ofthe containers or apparatus via one or more shuttle conveyors (950).

FIG. 29 illustrates an embodiment of an overall system (1000) of theinvention that includes an integrated sanitization, precooling and MAPprocess with a cross dock arrangement. In this embodiment, the system(1000) includes a combination sanitization and precooling container orunit (915) just loaded, a completed sanitized and precooled container orunit (1015), and an automated, modified atmosphere pallet (MAP)application system (930). In this embodiment, pallets of harvested,perishable product are first transported to the system (1000) via atruck or semi-trailer (1020) from the field after harvesting of theproduct. The pallets of product are thereafter moved or transported tothe combination sanitization and precooling container (915) fortreatment with a sanitizer to reduce spoilage or pathogenic organismsthat may be present on the surface of the product, while also coolingthe product to a desirable temperature (e.g., 32-34° F.). Aftertreatment and cooling is completed, the perishable product, asdemonstrated in unit (1015), is moved to the automated, modifiedatmosphere pallet (MAP) application system (930) to add an MAP to theproduct. Although the MAP system (930) in this embodiment is automated,the MAP system (930) could also be semi-automatic. Once the pallets havecompleted the application in the MAP system (930), the pallets arefinally moved or transported to a final shipping semi-trailer (960) fortransportation to a storage warehouse or other location. According tothis embodiment, pallets of perishable product are moved or transportedbetween each of the containers or apparatus via one or more shuttleconveyors (950).

FIG. 30 illustrates an embodiment of an overall system (2000) of theinvention that includes an integrated sanitization, precooling and MAPprocess with a cross dock arrangement. In this embodiment, the system(2000) includes a plurality of combination sanitization and precoolingcontainers or units (915A, 915B, 915C, and 915D) just loaded and anautomated, modified atmosphere pallet (MAP) application system (930).The system (2000) further includes a plurality of staging areas (2015A,2015B, 2015C, and 2015D) in which completed cooled and sanitizedproducts are held after the cooling and sanitization treatment.Additionally, this system (2000) includes one or more robot palletcarriers (2020) for delivering the completed cooled and sanitizedproducts from the staging areas (2015A, 2015B, 2015C, and 2015D) to theautomated, modified atmosphere pallet (MAP) application system (930). Inthis embodiment, pallets of harvested, perishable product are firsttransported to the system (2000) via a plurality of trucks orsemi-trailers (1020A, 1020B, 1020C, and 1020D) from the field afterharvesting of the product(s). The pallets of product are thereaftermoved or transported to the combination sanitization and precoolingcontainers (915A, 915B, 915C, and 915D) for treatment with a sanitizerto reduce spoilage or pathogenic organisms that may be present on thesurface of the product, while also cooling the product to a desirabletemperature (e.g., 32-34° F.). After treatment and cooling is completed,the cooled and sanitized perishable product is positioned in the one ormore staging areas (2015A, 2015B, 2015C, and 2015D), and thereafter, thecooled and sanitized perishable product is moved, via the one or morerobot pallet carriers (2020), to the automated, modified atmospherepallet (MAP) application system (930) to add an MAP to the product.Although the MAP system (930) in this embodiment is automated, the MAPsystem (930) could also be semi-automatic. Once the pallets havecompleted the application in the MAP system (930), the pallets arefinally moved or transported to a final shipping semi-trailer (960) fortransportation to a storage warehouse or other location. According tothis embodiment, pallets of perishable product are moved or transportedbetween each of the containers or apparatus via one or more shuttleconveyors (950) and/or one or more robot pallet carriers (2020).

FIG. 31 illustrates another embodiment of an overall system (3000) ofthe invention that includes an integrated sanitization, precooling andMAP process with a cross dock arrangement. In this embodiment, thesystem (3000) includes a plurality of combination sanitization andprecooling containers or units (915A, 915B, 915C, and 915D) just loadedand an automated, modified atmosphere pallet (MAP) application system(930). The system (3000) further includes a plurality of staging areas(2015A, 2015B, 2015C, and 2015D) in which completed cooled and sanitizedproducts are held after the cooling and sanitization treatment.Additionally, this system (3000) includes one or more robot palletcarriers (2020) for delivering the completed cooled and sanitizedproducts from the staging areas (2015A, 2015B, 2015C, and 2015D) to theautomated, modified atmosphere pallet (MAP) application system (930).Moreover, this system (3000) includes an automated mixed pallet picker(3030) in which completed cooled and sanitized products are delivered,via, e.g., one or more robot pallet carriers (2020), from the stagingareas (2015A, 2015B, 2015C, and 2015D), in order to provide a mixedpallet of perishable product (3050) to the automated, modifiedatmosphere pallet (MAP) application system (930) and thereafter, to asemi-trailer (960) for transportation to a storage warehouse or otherlocation. In this embodiment, pallets of harvested, perishable productare first transported to the system (3000) via a plurality of trucks orsemi-trailers (1020A, 1020B, 1020C, and 1020D) from the field afterharvesting of the product(s). The pallets of product are thereaftermoved or transported to the combination sanitization and precoolingcontainers (915A, 915B, 915C, and 915D) for treatment with a sanitizerto reduce spoilage or pathogenic organisms that may be present on thesurface of the product, while also cooling the product to a desirabletemperature (e.g., 32-34° F.). After treatment and cooling is completed,the cooled and sanitized perishable product is positioned in the one ormore staging areas (2015A, 2015B, 2015C, and 2015D). Thereafter, thecooled and sanitized perishable product is moved, via the one or morerobot pallet carriers (2020), to (i) the automated, modified atmospherepallet (MAP) application system (930) to add an MAP to the product or(ii) the automated mixed pallet picker (3030) and then to the automated,modified atmosphere pallet (MAP) application system (930) to add an MAPto the mixed pallet of perishable product (3050). Although the MAPsystem (930) and the mixed pallet picker (3030) in this embodiment areautomated, either or both of the MAP system (930) and the mixed palletpicker (3030) could also be semi-automatic. Once the pallets havecompleted the application in the MAP system (930), the pallets arefinally moved or transported to a final shipping semi-trailer (960) fortransportation to a storage warehouse or other location. According tothis embodiment, pallets of perishable product are moved or transportedbetween each of the containers or apparatus via one or more shuttleconveyors (950) and/or one or more robot pallet carriers (2020).

FIG. 32 illustrates another embodiment of a precooling container (4000)of the invention in which a refrigeration/cooling and pressure air flowunit (4020) is included within a portion (4025) of the container (4000).The refrigeration/cooling and pressure air flow unit (4020) includes,for example, fans and/or cooling coils to provide the necessary coolingcapacity to the container (4000). Air (i.e., positive pressure air flow(4060)) is forced through a pallet(s) (4050) of cartons of product (seehorizontal and/or vertical arrows in FIG. 32). The air returns up andover the pallets (4050) back to the refrigeration/cooling and pressureair flow unit (4020). A tarp material (4100) is also provided betweenthe refrigeration/cooling and pressure air flow unit (4020) and thepallet(s) (4050) in order to seal the pallet(s) (4050) and effectivelyforce the positive pressure air flow (4060) through the pallet(s)(4050). Additionally, according to this embodiment, a programmablecontroller (4070) and one or more sensors (4080) are included with thecontainer (4000). The one or more sensors (4080) measure variousparameters within the container (4000) including, e.g., a concentrationof sanitizing substances in the air to achieve a prescribed treatment, apresence of at least one airborne microorganism to determine when toconclude a sanitizing treatment cycle, a pulp temperature of theperishable product to determine when to conclude a precooling cycle, theenvironment to determine when to conclude a venting and scrubbing ofcontainer gasses to enable removal of the product, and/or liquidcondensate to determine treatment for wastewater removal. The one ormore sensors (4080) is configured to supply the collected data relatingto the various parameters to the programmable controller (4070) in whicha control program having a prescribed recipe is saved, which allows forthe controller (4070) to adjust one or more parameters of the process bysending a control signal to one or more of the refrigeration/cooling andpressure air flow unit (4020), a humidity system (not shown), an ozonefeed system (not shown), a venting system (not shown), and/or asubstance spraying system (see, e.g., treatment sprayer 5040 of FIGS.33A and 33B), to achieve a target cooling rate, relative humidity,atmosphere level, substance treatment level, and/or microorganism countreduction.

FIGS. 33A and 33B illustrate an embodiment of a combined precooling andtreatment unit or container of the invention in which a 40′ container(5000) (or, alternatively, a 53′ semi-trailer) is modified by attachingor clipping at least one cooling system (5020) onto at least one side(5010) of the container (5000). The at least one cooling system (5020)is attached to the at least one side (5010) of the container (5000),with the at least one side (5010) being modified to enable (i) aprescribed refrigeration and pressure air flow (5025) and (ii) airrecirculation (horizontal and/or vertical arrows) across pallets (5050)of perishable product, as depicted in FIGS. 33A and 33B. The at leastone cooling system (5020) includes fans (5022) and cooling coils (5024)to provide the necessary cooling capacity to the container (5000).Additionally, according to this embodiment, a treatment sprayer (5040)can be included to provide a gaseous or vaporized sanitizer to thecontainer (5000) and/or air flow plenum to be recirculated through thepallets (5050) of perishable product. Moreover, according to thisembodiment, a single row of pallets (5050) of perishable product isprovided within the container (5000).

FIGS. 34A and 34B illustrate an embodiment of a combined precooling andtreatment unit or container of the invention in which a 40′ container(6000) (or, alternatively, a 53′ semi-trailer) is modified by attachingor clipping at least one cooling system or “reefer” (6020) onto at leastone side (6010) of the container (6000). The at least one cooling systemor “reefer” (6020) is held by a flatbed trailer (6500) and attached tothe at least one side (6010) of the container (6000), with the at leastone side (6010) being modified to enable (i) a prescribed refrigerationand pressure air flow (6025) and (ii) air recirculation (horizontaland/or vertical arrows) across pallets (6050) of perishable product, asdepicted in FIGS. 34A and 34B. The at least one cooling system or“reefer” (6020), which is held by the flatbed trailer (6500), isgenerally attached to the at least one side (6010) of the container(6000) via a pop-out side and/or attachment member (6400). The at leastone cooling system or “reefer” (6020) includes fans (6022) and coolingcoils (6024) to provide the necessary cooling capacity to the container(6000). The flatbed trailer (6500) can further hold (i) a refrigerantcondenser unit (6200) to provide necessary cooling capacity to the atleast one cooling system or “reefer” (6020) and (ii) a functionalsubstance addition system (6100) to provide gaseous or vaporizedsanitizer substances to the container (6000). In particular, accordingto this embodiment, a plurality of treatment sprayers (6040) areincluded to provide a gaseous or vaporized sanitizer from the functionalsubstance addition system (6100) to the container (6000) and/or air flowplenum to be recirculated through the pallets (6050) of perishableproduct. Moreover, according to this embodiment, a single row of pallets(6050) of perishable product is provided within the container (6000).

FIGS. 35A and 35B illustrate an embodiment of a combined precooling andtreatment unit or container of the invention in which a 40′ container(7000) (or, alternatively, a 53′ semi-trailer) is modified by attachingor clipping a cooling system (7020) onto each side (7010A and 7010B) ofthe container (7000). Each cooling system (7020) is attached to therespective side (7010A and 7010B) of the container (7000) via a “popout” side (7025A and 7025B) (see also, e.g., embodiment described abovewith respect to FIGS. 9, 10A, and 10B), with each side (7010A and 7010B)of the container (7000) being modified to enable (i) a prescribedrefrigeration and pressure air flow and (ii) air recirculation(horizontal and/or vertical arrows) across two rows of pallets (7050Aand 7050B) of perishable product, as depicted in FIGS. 35A and 35B. Eachcooling system (7020) includes fans (7022) and cooling coils (7024) toprovide the necessary cooling capacity to the container (7000).Moreover, according to this embodiment, as described above, two rows ofpallets (7050A and 7050B) of perishable product are provided within thecontainer (7000).

FIGS. 36A and 36B illustrate another embodiment of a combined precoolingand treatment unit or container of the invention in which a 40′container (8000) (or, alternatively, a 53′ semi-trailer) is modified byattaching or clipping at least one cooling system (8020) onto at leastone side (8010) of the container (8000). The at least one cooling system(8020) is attached to the at least one side (8010) of the container(8000), with the at least one side (8010) being modified to enable (i) aprescribed refrigeration and pressure air flow and (ii) airrecirculation across pallets of perishable product (not shown). The atleast one cooling system (8020) includes fans (8022) and cooling coils(8024) to provide the necessary cooling capacity to the container(8000). Additionally, according to this embodiment, a track system(8100) is included on which the at least one cooling system (8020) ispositioned. This track system (8100) allows for the at least one coolingsystem (8020) to be slid into and out of the container (8000). As shownin the embodiment of FIGS. 36A and 36B, the at least one cooling system(8020) is provided along the side (8010) of the container (8000) or theat least one cooling system (8020′) is positioned within the container(8000), with the track system (8100) allowing for this movement of theat least one cooling system (8020/8020′).

FIGS. 37A and 37B illustrate an alternative embodiment of a precoolingsystem of the invention in which a pre-cooling plenum (9010) is combinedwith a refrigeration zone (9020) in a single mobile unit (9000), suchas, e.g., a 53-foot mobile trailer. The pre-cooling plenum (9010), inwhich a plurality of pallets of perishable product can be placed intothe unit (9000) via a door (9060) (see, e.g., pallet 9070 of FIG. 37B),includes a plurality of cooling fans (9030) and/or cooling coils (9035)and/or pallet sealing pads (9045), such as, e.g., a cushion material toseal the top of a pallet (see, e.g., pallet 9070 of FIG. 37B). Accordingto one embodiment, the pre-cooling plenum (9010) includes at least tencooling fans (9030) for forced air recirculation and an evaporation coil(9035). The refrigeration zone (9020) includes one or more cooling fans(9040) and a refrigeration unit (9050) having a refrigeration compressorand condenser. The one or more cooling fans (9040) keep the air cool inthe refrigeration zone (9020), which can be in a nose (or front end) ofthe single mobile unit (9000) (e.g., trailer), according to oneembodiment. The refrigeration zone (9020), which includes the coolingfans (9040) and the refrigeration unit (9050), is configured to providethe necessary cooling capacity to the pre-cooling plenum (9010) of thesingle mobile unit (9000). It does this by cooling the refrigerant usedin the evaporator coil (9035). For example, the cooling fans (9030)cause cool air to be recirculated through the one or more pallets (9070)of product and across the evaporator coil (9035) (see, e.g., horizontaland/or vertical arrows in FIG. 37B). Additionally, according to thisembodiment, one or more treatment sprayers (9080) can be included toprovide a gaseous, vaporized, and/or atomized functional substancetreatment (e.g., sanitizer) to the one or more pallets (9070) ofproduct.

According to the embodiment of FIGS. 37A and 37B, in the case in which a53-foot mobile trailer is used as the single mobile unit (9000), theunit (9000) can have inside dimensions of, e.g., over 8 feet wide and 8feet high. In addition, according to one embodiment, a plurality ofpallets (9070) can be placed within this single mobile unit (9000), witheach pallet (9070) having dimensions of, for example, 40 inches in widthby 84 inches in height.

FIG. 38 is a flowchart of an embodiment of the inventive process using amobile or prefabricated container designed to cool and to sanitizeproduct that is grown in a greenhouse growing facility, while also beingable to provide an optional MAP process (with a sanitizer treatment). Inthis process, a perishable product is grown and harvested within agreenhouse growing facility. According to one embodiment, the harvestedproduct is then packed within a container and placed on a packing lineto be packaged and palleted for a consumer. According to anotherembodiment, after harvesting the product from the greenhouse growingfacility, the harvested product is directly packed into aconsumer/retail package and palletized. The pallets of product are thencooled and sanitized/treated within a mobile container (as discussed inone or more of the embodiments above). After cooling and sanitizing thepallets of product, the pallets are staged for shipping. At this point,the cooled and sanitized pallets of product can optionally be treatedwith an MAP process with (or without) an additional sanitizer treatment.After the pallets are staged for shipping (or finish with the optionalMAP process) via, e.g., a cross-docking configuration, which is furtherdiscussed below, the pallets are shipped to a customer(s).

FIG. 39 illustrates an embodiment of the inventive process illustratedin FIG. 38 that uses one or more mobile or prefabricated containersdesigned to cool and to sanitize product that is grown in a greenhousegrowing facility. As shown in FIG. 39, at least two greenhousefacilities (A and B) are used to grow and harvest one or more types ofperishable product. The harvested product from each of the greenhousefacilities (A and B) is placed within containers (e.g., consumerpackages/pallets and/or containers to be further packaged/palletized onpacking lines (9110)) to be stored within a post-harvest storage area(9120). The pallets of product are then placed within one or moremodified, mobile or prefabricated containers (9100) to cool and to applythe sanitizing treatment before shipment. According to one embodiment,an additional refrigeration unit (9160) can be positioned next to theone or more modified, mobile or prefabricated containers (9100) forproviding additional cooling capacity to the one or more modified,mobile or prefabricated containers (9100). The cooled and sanitizedpallets of product are staged for shipping in a shipping staging area(9130). At this point, the cooled and sanitized pallets of product canoptionally be treated with an MAP process (9140) with (or without) anadditional sanitizer treatment. After the pallets are staged forshipping (or finish with the optional MAP process (9140)), the palletsare placed within semi-trailers (9150) to ship the pallets to one ormore customers. The embodiment of FIG. 39 is considered a “cross-dock”arrangement because the greenhouse facilities (A and B) are integratedwith a post-harvest storage area (9120) having (i) one or more modified,mobile or prefabricated containers (9100) to cool and to apply thesanitizing treatment to pallets of product on one side of thepost-harvest storage area (9120), and (ii) shipping area havingsemi-trailers (9150) on an opposite side of the post-harvest storagearea (9120). Thus, the one or more modified, mobile or prefabricatedcontainers (9100) to cool and to apply the sanitizing treatment topallets of product are “cross-docked” from a shipping area havingsemi-trailers (9150).

FIG. 40 is a flowchart of another embodiment of the inventive processusing a mobile or prefabricated container designed to cool and tosanitize product that is grown in a greenhouse growing facility, whilealso being able to provide an optional MAP process (with a sanitizertreatment). In this process, a perishable product is grown and harvestedwithin a greenhouse growing facility. According to this embodiment,after harvesting the product from the greenhouse growing facility, theharvested product is directly packed into a consumer/retail package andpalletized using, e.g., a packing line. The pallets of product are thencooled and sanitized/treated within a mobile or prefabricated container(as discussed in one or more of the embodiments above). After coolingand sanitizing the pallets of product, the pallets are staged forshipping. At this point, the cooled and sanitized pallets of product canoptionally be treated with an MAP process with (or without) anadditional sanitizer treatment. After the pallets are staged forshipping (or finish with the optional MAP process) via, e.g., across-docking configuration, which is further discussed below, thepallets are shipped to a customer(s).

FIG. 41 illustrates an embodiment of the inventive process illustratedin FIG. 40 that uses one or more mobile or prefabricated containersdesigned to cool and to sanitize product that is grown in a greenhousegrowing facility. As shown in FIG. 41, at least two greenhousefacilities (A and B) are used to grow and harvest one or more types ofperishable product. The harvested product from each of the greenhousefacilities (A and B) is placed within consumer/retail packages andpalletized via packing lines (9210) that are positioned within each ofthe greenhouse facilities (A and B). The pallets of product are thenpositioned within a shipping staging area (9230) where the pallets ofproduct can then be placed within one or more modified, mobile orprefabricated containers (9200) to cool and to apply the sanitizingtreatment before shipment. According to one embodiment, an additionalrefrigeration unit (9260) can be positioned next to the one or moremodified, mobile or prefabricated containers (9200) for providingadditional cooling capacity to the one or more modified, mobile orprefabricated containers (9200). The cooled and sanitized pallets ofproduct are staged for shipping in the shipping staging area (9230). Atthis point, the cooled and sanitized pallets of product can optionallybe treated with an MAP process (9240) with (or without) an additionalsanitizer treatment. After the pallets are staged for shipping (orfinish with the optional MAP process (9240)), the pallets are placedwithin semi-trailers (9250) to ship the pallets to one or morecustomers. The embodiment of FIG. 41 is also considered a “cross-dock”arrangement because the greenhouse facilities (A and B) are integratedwith a shipping staging area (9230) having (i) one or more modified,mobile or prefabricated containers (9200) to cool and to apply thesanitizing treatment to pallets of product on one side of the shippingstaging area (9230), and (ii) semi-trailers (9250) on an opposite sideof the shipping staging area (9230). Thus, the one or more modified,mobile or prefabricated containers (9200) to cool and to apply thesanitizing treatment to pallets of product are “cross-docked” from ashipping area having semi-trailers (9150).

According to another embodiment, one or more mobile or prefabricatedcontainers can be designed as a pass-thru unit or container to cool andto sanitize product that is grown in a greenhouse growing facility. Forexample, as shown in the embodiment of FIG. 42, at least two greenhousefacilities (A and B) are used to grow and harvest one or more types ofperishable product. The harvested product from each of the greenhousefacilities (A and B) is placed within consumer/retail packages andpalletized via packing lines (9310) that are positioned within each ofthe greenhouse facilities (A and B). The pallets of product are placedwithin one or more modified, mobile or prefabricated containers (9300)to cool and to apply the sanitizing treatment before shipment. The oneor more modified, mobile or prefabricated containers (9300) of FIG. 42are designed as “pass-thru” units or containers, as the pallets ofproduct pass directly into the one or more modified, mobile orprefabricated containers (9300) from the greenhouse facilities (A and B)via, e.g., a conveyor or pallet shuttle (9370). According to oneembodiment, an additional refrigeration unit (9360) can be positionednext to the one or more modified, mobile or prefabricated containers(9300) for providing additional cooling capacity to the one or moremodified, mobile or prefabricated containers (9300). At this point, thecooled and sanitized pallets of product can optionally be treated withan MAP process (9340) with (or without) an additional sanitizertreatment. Thereafter, the pallets of product are staged for shippingwithin a shipping area (9330) and then the pallets are placed withinsemi-trailers (9350) to ship the pallets to one or more customers. Inthe embodiment of FIG. 42, the one or more modified, mobile orprefabricated containers (9300) that are positioned as a “pass-thru”unit or container for cooling and applying the sanitizing treatment topallets of product are “cross-docked” from the shipping area (9330)having the semi-trailers (9350).

According to yet another embodiment, one or more mobile or prefabricatedcontainers can be designed as a pass-thru unit or container to cool andto sanitize product that is prepared and/or harvested in a meatprocessing facility. For example, as shown in the embodiment of FIG. 43,at least one meat processing facility or packing house (H) is usedprocess meat or other protein(s). The processed, prepared, and/orharvested product from the meat processing facility or packing house (H)is placed within consumer/retail packages and palletized via a packingline (9410) that is positioned within the meat processing facility orpacking house (H). The pallets of product are placed within one or moremodified, mobile or prefabricated containers (9400) to cool and to applythe sanitizing treatment before shipment. The one or more modified,mobile or prefabricated containers (9400) of FIG. 43 are designed as“pass-thru” units or containers, as the pallets of product pass directlyinto the one or more modified, mobile or prefabricated containers (9400)from the meat processing facility or packing house (H) via, e.g., aconveyor or pallet shuttle (9470). According to one embodiment, anadditional refrigeration unit (9460) can be positioned next to the oneor more modified, mobile or prefabricated containers (9400) forproviding additional cooling capacity to the one or more modified,mobile or prefabricated containers (9400). At this point, the cooled andsanitized pallets of product can optionally be treated with an MAPprocess (9440) with (or without) an additional sanitizer treatment.Thereafter, the pallets of product are staged for shipping within ashipping area (9430) and then the pallets are placed withinsemi-trailers (9450) to ship the pallets to one or more customers. Inthe embodiment of FIG. 43, the one or more modified, mobile orprefabricated containers (9400) that are positioned as a “pass-thru”unit or container for cooling and applying the sanitizing treatment topallets of product are “cross-docked” from the shipping area (9430)having the semi-trailers (9450).

FIG. 44 is a flowchart of an embodiment of the inventive process usingmultiple mobile or prefabricated containers that are integrated toconduct a harvest (e.g., greenhouse and/or field growing) to shippingoperation that includes bulk packaging of the harvested product. In thisprocess, a perishable product is grown and harvested within a greenhousegrowing facility and/or is field grown. According to one embodiment, theharvested product is then bulked packaged on a pallet. The pallets ofbulk packaged product are then precooled using, e.g., pressurizedcooling, and sanitized/treated within a mobile or prefabricatedcontainer (as discussed in one or more of the embodiments above).According to one embodiment, the pallets of bulk packaged product areeither partially cooled to an intermediate temperature or to a finalshipping temperature. After precooling and sanitizing the pallets ofbulk packaged product, a process line is used to sort and functionallytreat the product within a mobile or prefabricated container thatincludes, e.g., installed process equipment as described in furtherdetail below. According to one embodiment, during this sorting andfunctional treatment step, product is transferred onto a process line,debris and defects are removed, a wet or dry wash may be included and/orsanitization may be included, along with cooling, air drying, etc.Thereafter, the sorted and treated pallets of bulk packaged product arepacked within a consumer package using a packing line within a mobile orprefabricated container that includes, e.g., installed packing equipmentas described in further detail below. The consumer packaged product isplaced on pallets and then cooled using, e.g., pressurized cooling, andsanitized/treated within a mobile or prefabricated container (asdiscussed in one or more of the embodiments above). According to oneembodiment, the pallets of consumer packaged product are eitherpartially cooled to an intermediate temperature or to a final shippingtemperature. According to another embodiment, in this step, it ispossible to re-use the first precooling mobile or prefabricatedcontainer. At this point, the final cooled and sanitized pallets ofproduct can optionally be treated with an MAP process, i.e., a sealedpallet enclosure is created with a modified atmosphere, with (orwithout) an additional sanitizer or functional treatment. Thereafter,the pallets are staged for shipping and the pallets are shipped to acustomer(s). According to one embodiment, this process and the varioussteps of FIG. 44 can be conducted using, e.g., mobile or prefabricatedcontainers connected and integrated with conveyors and movable platformsfor a flow-through process (as discussed in one or more of theembodiments above).

FIG. 45 illustrates an embodiment of an overall system (9500) of theinvention that includes an integrated mobile, modular sanitization,cooling and packing process from harvest into bulk package with a crossdock arrangement. In this embodiment, the system (9500) includes a firstcombination sanitizing and cooling container (9540), a process linewithin a container (9550) to sort and/or functionally treat product inthe container (9550), a packing line within a container (9555), a secondcombination sanitizing and cooling container (9565), and an automated,modified atmosphere pallet (MAP) application system (9570). In thisembodiment, pallets of bulk packaged, harvested, perishable product(9530) are first transported to the system (9500) via a truck orsemi-trailer (9510) from the field after harvesting of the product. Thepallets of product (9530) are thereafter moved or transported using aconveyor belt (9520) to the first combination sanitizing and coolingcontainer (9540) for treatment with a sanitizer to reduce spoilage orpathogenic organisms that may be present on the surface of the product,while also cooling the product to a desirable temperature (e.g., 32-34°F.). After the initial treatment and cooling is completed, the cooledperishable product, as demonstrated in unit (9535), is moved via anotherconveyor belt (9545) to a process line within a container (9550) to sortand/or functionally treat the product in the container (9550).Thereafter, the sorted and treated product is moved to a packing linewithin a container (9555) to pack the product into consumer packages.Once consumer packed, the units of product (9536) are moved via anotherconveyor belt (9560) to the second combination sanitizing and coolingcontainer (9565) to further cool the product to an intermediatetemperature or to a final shipping temperature and to further sanitize,as necessary. After this final cooling step, the packaged product isoptionally transferred to an automated, modified atmosphere pallet (MAP)application system (9570) to add an MAP to the product. Although the MAPsystem (9570) in this embodiment is automated, the MAP system (9570)could also be semi-automatic. Once the pallets have completed theapplication in the MAP system (9570), the pallets (9538) are finallymoved or transported to a final shipping semi-trailer (9580) fortransportation to a storage warehouse or other location. According tothis embodiment, pallets of perishable product are moved or transportedbetween each of the containers or apparatus via one or more shuttleconveyors (9520, 9545, 9560).

FIG. 46 is a flowchart of an embodiment of the inventive process usingmultiple mobile or prefabricated containers that are integrated toconduct a harvest (e.g., greenhouse and/or field growing) to shippingoperation that includes first packing the harvested product intoconsumer packages. In this process, a perishable product is grown andharvested within a greenhouse growing facility and/or is field grown.According to one embodiment, the harvested product is then packed intoconsumer packages on a pallet. The pallets of consumer packaged productare then precooled using, e.g., pressurized cooling, andsanitized/treated within a mobile or prefabricated container (asdiscussed in one or more of the embodiments above). According to oneembodiment, the pallets of consumer packaged product are eitherpartially cooled to an intermediate temperature or to a final shippingtemperature. After precooling and sanitizing the pallets of consumerpackaged product, the consumer packaged product is unpalletized and thena process line is used to functionally treat the product within a mobileor prefabricated container that includes, e.g., installed processequipment as described in further detail below. According to oneembodiment, during this step, product is transferred onto a processline, a wet or dry wash may be included and/or sanitization may beincluded, along with cooling, air drying, etc. Thereafter, the consumerpackaged product is re-palletized within the same mobile orprefabricated container that includes, e.g., installed process equipmentas described in further detail below. The consumer packaged product isthen cooled using, e.g., pressurized cooling, and sanitized/treatedwithin a mobile or prefabricated container (as discussed in one or moreof the embodiments above). According to one embodiment, the pallets ofconsumer packaged product are either partially cooled to an intermediatetemperature or to a final shipping temperature. According to anotherembodiment, in this step, it is possible to re-use the first precoolingmobile or prefabricated container. At this point, the final cooled andsanitized pallets of product can optionally be treated with an MAPprocess, i.e., a sealed pallet enclosure is created with a modifiedatmosphere, with (or without) an additional sanitizer or functionaltreatment. Thereafter, the pallets are staged for shipping and thepallets are shipped to a customer(s). According to one embodiment, thisprocess and the various steps of FIG. 46 can be conducted using, e.g.,mobile or prefabricated containers connected and integrated withconveyors and movable platforms for a flow-through process (as discussedin one or more of the embodiments above).

FIG. 47 illustrates an embodiment of an overall system (9600) of theinvention that includes an integrated mobile, modular sanitization,cooling and packing process from harvest into consumer packages with across dock arrangement. In this embodiment, the system (9600) includes afirst combination sanitizing and cooling container (9640), a processline within a container (9650) to functionally treat product in thecontainer (9650), a second combination sanitizing and cooling container(9665), and an automated, modified atmosphere pallet (MAP) applicationsystem (9670). In this embodiment, pallets of consumer packaged,harvested, perishable product (9630) are first transported to the system(9600) via a truck or semi-trailer (9610) from the field afterharvesting and packing of the product. The pallets of product (9630) arethereafter moved or transported using a conveyor belt (9620) to thefirst combination sanitizing and cooling container (9640) for treatmentwith a sanitizer to reduce spoilage or pathogenic organisms that may bepresent on the surface of the product, while also cooling the product toa desirable temperature (e.g., 32-34° F.). After the initial treatmentand cooling is completed, the cooled perishable product, as demonstratedin unit (9635), is moved via another conveyor belt (9645) to a processline within a container (9650) to functionally treat the product in thecontainer (9650). Thereafter, the units of treated product (9636) aremoved via the conveyor belt (9620) to the second combination sanitizingand cooling container (9665) to further cool the product to anintermediate temperature or to a final shipping temperature and tofurther sanitize, as necessary. After this final cooling step, thepackaged product is optionally transferred to an automated, modifiedatmosphere pallet (MAP) application system (9670) to add an MAP to theproduct. Although the MAP system (9670) in this embodiment is automated,the MAP system (9670) could also be semi-automatic. Once the palletshave completed the application in the MAP system (9670), the pallets(9638) are finally moved or transported to a final shipping semi-trailer(9680) for transportation to a storage warehouse or other location.According to this embodiment, pallets of perishable product are moved ortransported between each of the containers or apparatus via one or moreshuttle conveyors (9620, 9645).

FIG. 48 illustrates another embodiment of an overall system (9700) ofthe invention that includes an integrated mobile, modular sanitization,cooling and packing process from harvest with a cross dock arrangement.In this embodiment, which is a smaller operation than the embodiments ofFIGS. 45 and 47, the system (9700) includes a single combinationsanitizing and cooling container (9740), a combination process andpacking line within a container (9750) to functionally treat and packproduct in the container (9750), and an automated, modified atmospherepallet (MAP) application system (9770). In this embodiment, pallets ofharvested, perishable product (9730), which can be either bulk packagedor consumer packaged, are first transported to the system (9700) via atruck or semi-trailer (9710) from the field after harvesting of theproduct. The pallets of product (9730) are thereafter moved ortransported using a conveyor belt (9720) to the single combinationsanitizing and cooling container (9740) for treatment with a sanitizerto reduce spoilage or pathogenic organisms that may be present on thesurface of the product, while also cooling the product to a desirabletemperature (e.g., 32-34° F.). After this treatment and cooling iscompleted, the cooled perishable product, as demonstrated in unit(9735), is moved via another conveyor belt (9745) to a combinationprocess and packing line within a container (9750) to functionally treatand pack the product in the container (9750). Thereafter, the units oftreated and packaged product (9736) are optionally transferred to anautomated, modified atmosphere pallet (MAP) application system (9770) toadd an MAP to the product. Although the MAP system (9770) in thisembodiment is automated, the MAP system (9770) could also besemi-automatic. Once the pallets have completed the application in theMAP system (9770), the pallets (9738) are finally moved or transportedto a final shipping semi-trailer (9780) for transportation to a storagewarehouse or other location. According to this embodiment, pallets ofperishable product are moved or transported between each of thecontainers or apparatus via one or more shuttle conveyors (9720, 9745).

FIG. 49 is a flowchart of an embodiment of the inventive process usingmultiple mobile or prefabricated containers that are integrated toconduct a harvest (e.g., greenhouse and/or field growing) to shippingoperation that includes first bulk packaging of the harvested product.In this process, a perishable product is grown and harvested within agreenhouse growing facility and/or is field grown. According to oneembodiment, the harvested product is then bulked packaged on a pallet.The pallets of bulk packaged product are then precooled using, e.g.,pressurized cooling, and sanitized/treated within a mobile orprefabricated container (as discussed in one or more of the embodimentsabove). According to one embodiment, the pallets of bulk packagedproduct are either partially cooled to an intermediate temperature or toa final shipping temperature. After precooling and sanitizing thepallets of bulk packaged product, a process line is used to sort andfunctionally treat the product within a mobile or prefabricatedcontainer that includes, e.g., installed process equipment as describedin further detail below. According to one embodiment, during thissorting and functional treatment step, product is transferred onto aprocess line, debris and defects are removed, a wet or dry wash may beincluded and/or sanitization may be included, along with cooling, airdrying, etc. Thereafter, the sorted and treated pallets of bulk packagedproduct are packed within a consumer package using a packing line withina mobile or prefabricated container that includes, e.g., installedpacking equipment as described in further detail below. According to oneembodiment, multiple connected mobile containers or pre-fabricatedmovable units, containers or buildings on trailers with installedprocess equipment are used to house (i) the process line to sort andfunctionally treat the product and (ii) the packing line to package theproduct into consumer packages. The consumer packaged product is placedon pallets and then cooled using, e.g., pressurized cooling, andsanitized/treated within a mobile or prefabricated container (asdiscussed in one or more of the embodiments above). According to oneembodiment, the pallets of consumer packaged product are eitherpartially cooled to an intermediate temperature or to a final shippingtemperature. According to another embodiment, in this step, it ispossible to re-use the first precooling mobile or prefabricatedcontainer. At this point, the final cooled and sanitized pallets ofproduct can optionally be treated with an MAP process, i.e., a sealedpallet enclosure is created with a modified atmosphere, with (orwithout) an additional sanitizer or functional treatment. Thereafter,the pallets of consumer packaged product can be placed into coldstorage, which can be within one or more mobile refrigerated containers,until the pallets are ready to be shipped to a customer(s). According toone embodiment, this process and the various steps of FIG. 49 can beconducted using, e.g., mobile or prefabricated containers connected andintegrated with conveyors and movable platforms for a flow-throughprocess (as discussed in one or more of the embodiments above).

FIG. 50 illustrates an embodiment of an overall system (9800) of theinvention that includes an integrated mobile, modular sanitization,cooling and packing operation from harvest into bulk packages with across dock arrangement. In this embodiment, the system (9800) includes afirst combination sanitizing and cooling container (9840), a processline within a container (9850B) to functionally treat product in thecontainer (9850B), a packing line within a container (9850A) to pack theproduct into consumer packages in the container (9850A), a secondcombination sanitizing and cooling container (9865), an automated,modified atmosphere pallet (MAP) application system (9870), and one ormore mobile, cold storage containers (9875). In this embodiment, palletsof bulk packaged, harvested, perishable product (9830) are firsttransported to the system (9800) via a truck or semi-trailer (9810) fromthe field after harvesting and packing of the product. The pallets ofproduct (9830) are thereafter moved or transported using a conveyor belt(9820) to the first combination sanitizing and cooling container (9840)for treatment with a sanitizer to reduce spoilage or pathogenicorganisms that may be present on the surface of the product, while alsocooling the product to a desirable temperature (e.g., 32-34° F.). Afterthe initial treatment and cooling is completed, the cooled perishableproduct, as demonstrated in unit (9835), is moved via another conveyorbelt (9845) to a process line within a container (9850B) to functionallytreat the product in the container (9850B). Thereafter, the treatedproduct is moved to a packing line within a container (9850A) to packthe product into consumer packages. According to this embodiment,multiple connected mobile containers or pre-fabricated buildings,containers or units on trailers can be used to contain the full processand packing line infrastructure. Once consumer packed, the units ofproduct (9836) are moved via the conveyor belt (9820) to the secondcombination sanitizing and cooling container (9865) to further cool theproduct to an intermediate temperature or to a final shippingtemperature and to further sanitize, as necessary. After this finalcooling step, the packaged product is optionally transferred to anautomated, modified atmosphere pallet (MAP) application system (9870) toadd an MAP to the product. Although the MAP system (9870) in thisembodiment is automated, the MAP system (9870) could also besemi-automatic. Once the pallets have completed the application in theMAP system (9870), the pallets (9838) can be placed into cold storage,which is within one or more mobile refrigerated or cold storagecontainers (9875), until the pallets (9839) are ready to be finallymoved or transported to a final shipping semi-trailer (9880) fortransportation to a storage warehouse or other location. According tothis embodiment, pallets of perishable product are moved or transportedbetween each of the containers or apparatus via one or more shuttleconveyors (9820, 9845).

FIG. 51 illustrates an embodiment of an overall system (9900) of theinvention that includes an integrated mobile, modular sanitization,cooling and packing process/operation from harvest into bulk packagewith a cross dock arrangement. In this embodiment, the system (9900)includes a first staging area (9910) that includes one or morecontainers with in-bound harvested product. According to one embodiment,containers that include pallets of bulk packaged, harvested, perishableproduct are first transported to the first staging area (9910) via atruck or semi-trailer (not shown) from the field after harvesting of theproduct. The pallets of product are thereafter moved or transported to afirst combination precooling and sanitization container (9920) fortreatment with a sanitizer to reduce spoilage or pathogenic organismsthat may be present on the surface of the product, while also coolingthe product to a desirable temperature (e.g., 32-34° F.). Prior toand/or after the initial treatment and precooling is completed, thecooled perishable product can be stored in one or more cold storagecontainers (9925), which comprise, e.g., 40′ containers or 48′ reefertrailers that store the cooled in-bound perishable product. Thereafter,the cooled product can be moved to connected and integrated containers,trailers, and/or prefabricated units (9940) that include (i) aprocessing line(s) within the containers (9940) to sort and/orfunctionally treat the product in the containers (9940) and (ii) apacking line(s) within the containers (9940) to pack the product intoconsumer packages. Once consumer packed, the units of product are movedto a second (or final) combination cooling and sanitization container(9960) to further cool the product to an intermediate temperature or toa final shipping temperature and to further sanitize, as necessary.After this final cooling step, the packaged product is optionallytransferred to an automated, modified atmosphere pallet (MAP)application system (9955) to add an MAP to the product. Although the MAPsystem (9955) in this embodiment is automated, the MAP system (9955)could also be semi-automatic. Once the pallets have completed theapplication in the MAP system (9955), the pallets can be placed into oneor more cold storage containers (9965), which comprise, e.g., 40′containers or 48′ reefer trailers that store the cooled, finishedperishable product, until the pallets are ready to be moved ortransported to final shipping semi-trailers (9970) (such as, e.g., 48′reefer trailers) for transportation to a storage warehouse or otherlocation. As further shown in the embodiment of FIG. 51, storagetrailers (9930) (such as, e.g., 48′ trailers) can be included within thesystem (9900) to store packing materials. In addition, one or morecontainers or trailers (9945) can be included to store used palletsand/or outbound harvest totes. Moreover, as shown in the embodiment ofFIG. 51, each of the containers or trailers in the system (9900) can beconnected and/or integrated with a covered cross-dock (9950) to allowfor ease in transfer of pallets of product between each of thecontainers and/or trailers. According to one embodiment, pallets ofperishable product can be moved or transported between each of thecontainers or apparatus and/or the covered cross-dock (9950) via one ormore shuttle conveyors.

FIG. 52 illustrates an embodiment of a combined or integrated containerof the invention that includes both a process line and a packing line,in which a mobile or prefabricated container (10000) is modified toinclude a process or product inspection line (10300), a treatment system(10500), and one or more packing lines (10600). According to theembodiment of FIG. 52, the container (10000) includes an in-bound door(10100) in which perishable product that has been harvested from a fieldand/or a greenhouse is brought into the container (10000). Pallets ofproduct can enter the in-bound door (10100) of the system (10000) and bekept in a staging area (10200) until ready for product inspection. Atthe process or product inspection line (10300), the product is inspectedto remove any debris and/or defects, with any waste from the culls beingremoved from the system (10000) via an output unit (10450). Thereafter,the inspected product can be moved to a second staging area (10400) (ora conveyor system) and into a treatment system (10500) to functionallytreat and/or sanitize the processed product. Thereafter, the treatedproduct can enter the one or more packing lines (10600) to pack theproduct into consumer packages. The consumer packaged product can bestored at a final staging area (10700) and thereafter at a completedproduct area (10800) where the final, consumer packaged product can beremoved from the system (10000) via an out-bound door (10900). As shownin the embodiment of FIG. 52, the system (10000) can also include aseparate area for (i) storing packing materials (10650) and (ii) holdinga treatment support unit (10500) that provides the necessary agents tothe treatment system (10500). This separate area of the container(10000) further includes a materials door (10660) in which the variousmaterials (e.g., packing materials, treatment agents, etc.) can bebrought into the system (10000).

FIG. 53 illustrates another embodiment of a combined or integratedcontainer of the invention that includes both a process line and apacking line, in which a mobile or prefabricated container (11000) ismodified to include a process or product inspection line (11300), afirst treatment system (11500), a second treatment system (11510), andone or more packing lines (11600). According to the embodiment of FIG.53, the container (11000) includes an in-bound door (11100) in whichperishable product that has been harvested from a field and/or agreenhouse is brought into the container (11000). Pallets of product canenter the in-bound door (11100) of the system (11000) and be kept in astaging area (11200) until ready for product inspection. At the processor product inspection line (11300), the product is inspected to removeany debris and/or defects, with any waste from the culls being removedfrom the system (11000) via an output unit (11450). Thereafter, theinspected product can be moved to a second staging area (11400) (or aconveyor system) and into a first treatment system (11500) tofunctionally treat and/or sanitize the processed product. Thereafter,the treated product can be moved into a second treatment system (11510)in order to further functionally treat and/or sanitize the product withone or more additional agents. According to an embodiment, the treatmentof the product in the second treatment system (11510) is the same as ordifferent from the treatment of the product in the first treatmentsystem (11500). Thereafter, the treated product can enter the one ormore packing lines (11600) to pack the product into consumer packages.The consumer packaged product can be stored at a final staging area(11700) and thereafter at a completed product area (11800) where thefinal, consumer packaged product can be removed from the system (11000)via an out-bound door (11900). As shown in the embodiment of FIG. 53,the system (11000) can also include a separate area for (i) storingpacking materials (11650) and (ii) holding a treatment support unit(11550) that provides the necessary agents to the first treatment system(11500) and the second treatment system (11510). This separate area ofthe container (11000) further includes a materials door (11660) in whichthe various materials (e.g., packing materials, treatment agents, etc.)can be brought into the system (11000).

FIG. 54A illustrates an embodiment of an overall system (12000) of theinvention that includes an integrated mobile, modular sanitization,cooling and packing operation with a cross dock arrangement, along withrobotic pallet handling. In this embodiment, the system (12000) includesa first combination sanitizing and cooling container (12300), a processline within a container (12500B) to functionally treat product in thecontainer (12500B), a packing line within a container (12500A) to packthe product into consumer packages in the container (12500A), a secondcombination sanitizing and cooling container (12600), an automated,modified atmosphere pallet (MAP) application system (12700), and one ormore mobile, cold storage containers (12800). In this embodiment,pallets of harvested, perishable product are first transported to thesystem (12000) via one or more robotic pallets (12100) from the fieldand/or greenhouse after harvesting and packing of the product. Therobotic pallets of product (12100) are thereafter moved or transportedusing a conveyor belt (12200) to the first combination sanitizing andcooling container (12300) for treatment with a sanitizer to reducespoilage or pathogenic organisms that may be present on the surface ofthe product, while also cooling the product to a desirable temperature(e.g., 32-34° F.). After the initial treatment and cooling is completed,the cooled perishable product, as demonstrated in unit (12150), is movedvia another conveyor belt (12400) to a process line within a container(12500B) to functionally treat the product in the container (12500B).Thereafter, the treated product is moved to a packing line within acontainer (12500A) to pack the product into consumer packages. Accordingto this embodiment, multiple connected mobile containers orpre-fabricated buildings, containers or units on trailers can be used tocontain the full process and packing line infrastructure. Once consumerpacked, the units of product (12160) are moved via the conveyor belt(12200) to the second combination sanitizing and cooling container(12600) to further cool the product to an intermediate temperature or toa final shipping temperature and to further sanitize, as necessary.After this final cooling step, the packaged product is optionallytransferred to an automated, modified atmosphere pallet (MAP)application system (12700) to add an MAP to the product. Although theMAP system (12700) in this embodiment is automated, the MAP system(12700) could also be semi-automatic. Once the pallets have completedthe application in the MAP system (12700), the pallets (12170) can beplaced into cold storage, which is within one or more mobilerefrigerated or cold storage containers (12800), until the pallets(12180) are ready to be finally moved or transported to a final shippingsemi-trailer (not shown), via an end (12900) of the system (12000), fortransportation to a storage warehouse or other location. According tothis embodiment, pallets of perishable product are moved or transportedbetween each of the containers or apparatus via one or more shuttleconveyors (12200, 12400).

FIG. 54B illustrates a robotic pallet according to one embodiment of theinvention that can be used within the system of FIG. 54A. As shown inFIG. 54B, the robotic pallet includes a pallet (12100) of product thatis positioned on top of a robotic unit (12110) that is capable ofrobotically transporting the pallet (12100) of product to an integratedsystem for a sanitization, cooling, and packing operation. According toone embodiment, the robotic pallets are integrated with operations tomove and position all pallets for each step of the process as needed tomaximize efficiency.

FIG. 55 illustrates an embodiment of an overall system (13000) of theinvention that includes an integrated mobile, modular sanitization,cooling and packing process/operation with a cross dock arrangementusing robotic pallet handling. In this embodiment, the system (13000)includes a first staging area (13100) that includes one or morecontainers with in-bound harvested product. According to one embodiment,containers that include pallets of bulk packaged, harvested, perishableproduct are first transported to the first staging area (13100) via atruck or semi-trailer (not shown) from the field after harvesting of theproduct. The pallets of product are thereafter moved or transported to afirst combination precooling and sanitization container (13200) fortreatment with a sanitizer to reduce spoilage or pathogenic organismsthat may be present on the surface of the product, while also coolingthe product to a desirable temperature (e.g., 32-34° F.). Prior toand/or after the initial treatment and precooling is completed, thecooled perishable product can be stored in one or more cold storagecontainers (13250), which comprise, e.g., 40′ containers or 48′ reefertrailers that store the cooled in-bound perishable product. Thereafter,the cooled product can be moved to connected and integrated containers,trailers, and/or prefabricated units (13400) that include (i) aprocessing line(s) within the containers (13400) to sort and/orfunctionally treat the product in the containers (13400) and (ii) apacking line(s) within the containers (13400) to pack the product intoconsumer packages. Once consumer packed, the units of product are movedto a second (or final) combination cooling and sanitization container(13600) to further cool the product to an intermediate temperature or toa final shipping temperature and to further sanitize, as necessary.After this final cooling step, the packaged product is optionallytransferred to an automated, modified atmosphere pallet (MAP)application system (13550) to add an MAP to the product. Although theMAP system (13550) in this embodiment is automated, the MAP system(13550) could also be semi-automatic. Once the pallets have completedthe application in the MAP system (13550), the pallets can be placedinto one or more cold storage containers (13650), which comprise, e.g.,40′ containers or 48′ reefer trailers that store the cooled, finishedperishable product, until the pallets are ready to be moved ortransported to final shipping semi-trailers (13700) (such as, e.g., 48′reefer trailers) for transportation to a storage warehouse or otherlocation. As further shown in the embodiment of FIG. 55, storagetrailers (13300) (such as, e.g., 48′ trailers) can be included withinthe system (13000) to store packing materials. In addition, one or morecontainers or trailers (13450) can be included to store used palletsand/or outbound harvest totes. Moreover, as shown in the embodiment ofFIG. 55, each of the containers or trailers in the system (13000) can beconnected and/or integrated with a covered cross-dock (13500) to allowfor ease in transfer of pallets of product between each of thecontainers and/or trailers. Additionally, according to this embodiment,robotic pallets (13800) are included to move or transport pallets ofperishable product between each of the containers or apparatus and/orthe covered cross-dock (13500). According to one embodiment, the roboticpallets (13800) are integrated with operations to move and position allpallets for each step of the process as needed to maximize efficiency.

FIG. 56 illustrates an embodiment of an overall system (14000) of theinvention that includes an integrated mobile, modular system with acovered-cooled interconnected cross-dock having a sanitization, cooling,and shipping operation from harvest into finished or bulk packages. Inthis embodiment, pallets of harvested, perishable product (14020) arefirst transported to the system (14000) via a truck or semi-trailer(14010) from the field after harvesting the product. The pallets ofproduct (14020), which are waiting to be sanitized and cooled, arethereafter moved or transported using, e.g., a conveyor belt (not shown)to a combination sanitizing and cooling container (14040) for treatmentwith a sanitizer to reduce spoilage or pathogenic organisms that may bepresent on the surface of the product, while also cooling the product toa desirable temperature (e.g., 32-34° F.). Before or after the initialtreatment and cooling is completed, the perishable product (14020 or14030) is moved via, e.g., another conveyor belt (not shown) to aprocess line within a container (14060) to functionally treat theproduct in the container (14060). Thereafter, the treated product ismoved either to (i) the combination sanitizing and cooling container(14040) for treatment with a sanitizer to reduce spoilage or pathogenicorganisms that may be present on the surface of the product, while alsocooling the product to a desirable temperature (e.g., 32-34° F.), or(ii) a packing line within a container (14050) to pack the sanitized andcooled product (14030) into bulk packages or finished/consumer packages.According to this embodiment, multiple (two or more) connected, modularmodified containers, refrigerated trailers, or sections ofpre-fabricated containers, units, or buildings on trailers can be usedto contain the full sanitizing, cooling, process and packing lineinfrastructure. Once bulk or consumer packed, the units of sanitized andcooled product (14030) are moved via, e.g., a conveyor belt (not shown)to another combination sanitizing and cooling container (represented byunit 14080) and/or an automated, modified atmosphere pallet (MAP)application system (represented by unit 14080) to (i) further cool theproduct to an intermediate temperature or to a final shippingtemperature and to further sanitize, as necessary, and/or (ii) to add anMAP to the product. Thereafter, the pallets (14030) can be optionallyplaced into cold storage, which is within one or more mobilerefrigerated or cold storage containers or reefer trailers (14090),until the pallets (14030) are ready to be finally moved or transportedto a final shipping semi-trailer (14100) for transportation to a storagewarehouse or other location. According to one embodiment, pallets ofperishable product are moved or transported between each of thecontainers or apparatus via one or more shuttle conveyors (not shown)and/or robotic pallets (not shown). Moreover, as shown in the embodimentof FIG. 56, each of the containers or trailers in the system (14000) canbe connected and/or integrated with a covered-cooled, interconnectedcross-dock (14070) to allow for ease in transfer of pallets of productbetween each of the containers and/or trailers. According to theembodiment of FIG. 56, a dual shuttle feed system (14000) is provided byconnecting a cooling and sanitization container unit (14040), withexternal pallet loading of non-cooled product (14020), and internal feedof cold product directly to a covered-cooled, interconnected cross-dock(14070) after cooling and sanitization of product (14030).

FIG. 57 illustrates an embodiment of the invention in which a combinedcooling and sanitization container(s) is integrated into an overallsystem and process, using cross-docking sanitization and cooling withoptional product handling, using modified refrigerated or insulatedtrailers, shipping containers, and/or prefabricated, modular movableunits or containers. In this embodiment, the system (15000) includes afirst staging area (15010) that includes one or more containers within-bound harvested product. According to one embodiment, containers thatinclude pallets of bulk packaged, harvested, perishable product arefirst transported to the first staging area (15010) via a truck orsemi-trailer (not shown) from the field after harvesting of the product.The pallets of product are thereafter moved or transported to a firstcombination precooling and sanitization container (15020) for treatmentwith a sanitizer to reduce spoilage or pathogenic organisms that may bepresent on the surface of the product, while also cooling the product toa desirable temperature (e.g., 32-34° F.). Prior to and/or after theinitial treatment and precooling is completed, the cooled perishableproduct can be stored in one or more cold storage containers (15040),which comprise, e.g., 40′ containers or 48′ or 53′ reefer trailers thatstore the cooled in-bound perishable product. The units of product canfurther be moved to a second (or final) combination cooling andsanitization container (15030) to further cool the product to anintermediate temperature or to a final shipping temperature and tofurther sanitize, as necessary. After this final cooling step, theproduct is optionally transferred to an automated, modified atmospherepallet (MAP) application system (not shown) to add an MAP to theproduct. Once the pallets have completed the sanitization and coolingstep(s) and/or the application in the MAP system (not shown), thepallets can be placed into the one or more cold storage containers(15040), which comprise, e.g., 40′ containers or 48′ or 53′ reefertrailers that store the cooled, finished perishable product, until thepallets are ready to be moved or transported to final shippingsemi-trailers (15070) (such as, e.g., 48′ or 53′ reefer trailers) fortransportation to a storage warehouse or other location. According toone embodiment, the final shipping semi-trailers (15070) (such as, e.g.,48′ or 53′ reefer trailers) can transport or ship the product forfurther processing and/or packaging. As further shown in the embodimentof FIG. 57, one or more containers or trailers (15060) can be includedto store used pallets and/or outbound harvest totes. Moreover, as shownin the embodiment of FIG. 57, each of the containers or trailers in thesystem (15000) can be connected and/or integrated with a coveredcross-dock (15050) to allow for ease in transfer of pallets of productbetween each of the containers and/or trailers. According to oneembodiment, pallets of perishable product can be moved or transportedbetween each of the containers or apparatus and/or the coveredcross-dock (15050) manually and/or via a forklift(s), one or moreshuttle conveyors, and/or one or more robotic pallets (15055).

FIGS. 58A and 58B illustrate the various functional operations andsystems for performing the cooling, sanitization, and/or functionaltreatment steps according to an embodiment of the invention. As shown inFIG. 58A, according to one embodiment, the overall system (16000) caninclude a plurality of independent and integrated steps, operations,and/or processes. For example, as shown in the embodiment of FIG. 58A,the overall system (16000) includes a sanitization process or step(16010), a mobile pre-cooling process or step (16020), an independent,modified atmosphere (MAP) process or step (16030), an integrated MAP andsanitization process or step (16040), and a combination of functionalingredients process or step (16050). Each of the operations, steps, orprocesses (16010, 16020, 16030, 16040, 16050) of the overall system(16000) of FIG. 58A can be included or not included depending uponoperation desired and/or the type of perishable product being harvestedand/or packaged.

FIG. 58B illustrates another embodiment of an overall system (16100)that includes a plurality of independent and integrated steps,operations, and/or processes to perform the cooling, sanitization,and/or functional treatment steps of the invention. For example, asshown in the embodiment of FIG. 58B, the overall system (16100) includesa systems approach (16110), process management and controls (16120),programmed substance treatments (16130), preferred substance delivery(16140), and a combination of functional ingredients (16150). Each ofthe operations, steps, or processes (16110, 16120, 16130, 16140, 16150)of the overall system (16100) of FIG. 58B can be included or notincluded depending upon operation desired and/or the type of perishableproduct being harvested and/or packaged.

FIG. 59 illustrates an embodiment of a system having a functionaltreatment and delivery platform for providing sanitization and/orfunctional treatment substances to a perishable product afterharvesting. As shown in the embodiment of FIG. 59, the system (17000)includes a water source (17010), an air source (17020), and anindustrial gas or carrier source (17030). The industrial gas or carriersource (17030) can be provided to one or more of a sanitizer (17060), afunctional substance A (17070), and a functional substance B (17075).According to one embodiment, the water source (17010) is provided to astorage tank (17015) in which the functional substance B (17075) is alsoprovided. From the storage tank (17015), the combined functionalsubstance B (17075) with the water source (17010) is provided to ametering apparatus (17080). According to another embodiment, the watersource (17010) is provided to an ionizer (17040). From the ionizer(17040), acidified, neutral, and/or alkaline water and/or substances arethereafter provided to the metering apparatus (17080). According to anembodiment, the air source (17020) is provided to an ozone generator(17050), which is thereafter provided to the metering apparatus (17080).According to an embodiment, one or more of the sanitizer (17060), thefunctional substance A (17070), and/or the functional substance B(17075) are provided directly to the metering apparatus (17080). Each ofthe substances and/or carriers that are provided to the meteringapparatus (17080) are thereafter provided to an atomizer (17090), whichis located within a precooling, sanitization and/or treatment chamber orcontainer (17100). The atomizer (17090) can thus deliver the varioussanitizers and/or functional treatment substances to a perishableproduct contained within the precooling, sanitization and/or treatmentchamber or container (17100). According to another embodiment, the airsource (17020) which is provided to an ozone generator (17050) can bedirectly fed into the precooling, sanitization and/or treatment chamberor container (17100). According to another embodiment, the sanitizer(17060) can be directly fed into the precooling, sanitization and/ortreatment chamber or container (17100).

According to one embodiment, the providing of sanitization and/orfunctional treatment substances to a perishable product after harvestingcan be conducted in accordance with one or more of the examplesdisclosed in PCT International Application Publication No. WO2021/055818, U.S. Patent Application Publication No. 2020/0281233, andPCT International Application Publication No. WO 2020/181228, each ofwhich are incorporated by reference herein in their entireties.

FIG. 60 illustrates an embodiment of an overall system (18000) of theinvention that includes an integrated mobile, modular sanitization,cooling and optional packing process/operation from harvest with across-dock arrangement. In this embodiment, the system (18000) includesa first staging area (18010) that includes one or more containers within-bound harvested product. According to one embodiment, containers thatinclude pallets of bulk packaged, harvested, perishable product arefirst transported to the first staging area (18010) via a truck orsemi-trailer (not shown) from the field after harvesting of the product.The pallets of product are thereafter moved or transported to a firstcombination precooling and sanitization container (18020) for treatmentwith a sanitizer to reduce spoilage or pathogenic organisms that may bepresent on the surface of the product, while also cooling the product toa desirable temperature (e.g., 32-34° F.). Prior to and/or after theinitial treatment and precooling is completed, the cooled perishableproduct can be stored in one or more cold storage containers (18025),which comprise, e.g., 40′ containers or 48′ or 53′ reefer trailers thatstore the cooled in-bound perishable product. According to oneembodiment, the cooled perishable product that is stored in the one ormore cold storage containers (18025) can thereafter be transferred toshipping semi-trailers (18030) (such as, e.g., 48′ or 53′ reefertrailers) to transport or ship the product for further processing and/orpackaging.

According to one embodiment, the cooled product can be optionally movedto connected and integrated containers, trailers, and/or prefabricatedunits (18040) that include (i) a processing line(s) within thecontainers (18040) to sort and/or functionally treat the product in thecontainers (18040) and (ii) a packing line(s) within the containers(18040) to pack the product into consumer packages. Once consumerpacked, the units of product are optionally moved to a second (or final)combination cooling and sanitization container (18060) to further coolthe product to an intermediate temperature or to a final shippingtemperature and to further sanitize, as necessary. After this finalcooling step, the packaged product is optionally transferred to anautomated, modified atmosphere pallet (MAP) application system (18055)to add an MAP to the product. Once the pallets have completed theapplication in the MAP system (18055), the pallets can be placed intoone or more cold storage containers (18065), which comprise, e.g., 40′containers or 48′ or 53′ reefer trailers that store the cooled, finishedperishable product, until the pallets are ready to be moved ortransported to final shipping semi-trailers (18070) (such as, e.g., 48′or 53′ reefer trailers) for transportation to a storage warehouse orother location and/or for distribution. As further shown in theembodiment of FIG. 60, storage trailers (18035) (such as, e.g., 48′trailers) can be included within the system (18000) to store packingmaterials. Moreover, as shown in the embodiment of FIG. 60, each of thecontainers or trailers in the system (18000) can be connected and/orintegrated with a covered cross-dock (18050) to allow for ease intransfer of pallets of product between each of the containers and/ortrailers. According to one embodiment, pallets of perishable product canbe moved or transported between each of the containers or apparatusand/or the covered cross-dock (18050) manually and/or via a forklift(s),one or more shuttle conveyors, and/or one or more robotic pallets(18080).

Although embodiments of the invention described herein include a mobilecontainer or a semi-trailer, other types of mobile or movable containersand/or units are contemplated in accordance with the principles of theinvention. For example, portions of the container, including, e.g., thewalls and/or shell of the unit, and/or refrigeration components can bepicked up and/or disassembled and placed on a truck for movement to alsobe mobile. Additionally, the containers and/or units can comprisepre-fabricated components, containers, and/or units or pre-fabricatedmodules for each postharvest process, including, e.g., the processinglines and/or packaging lines discussed above, that connect to form anintegrated system on site.

According to an embodiment of the invention, perishable products thatcan be cooled, treated, processed, and/or packaged, according to thevarious embodiments described above, include one or more of (i)pre-packed product after harvesting, (ii) bulk packed product into aharvest container to supply to a packing line, and (iii) product packedinto a partial container that needs additional handling/processing stepsto complete the packing of the harvested product.

Although embodiments of the invention described herein includeperishable products, such as berries, bananas, avocado, etc., variousother perishable products are able to be cooled by the modifiedcontainer and/or semi-trailer of the invention. For example, perishableproducts include, but are not limited to, lettuce products, basil,broccoli, beans, cucumbers, eggplants, squash and other herbs andvegetables, tomatoes, berries, cherries, grapes, peaches, melons andother fruit, or highly perishable produce. According to embodiments, theperishable product is a protein including but not limited to meat, fish,fowl, and vegetable protein products. According to embodiments, theperishable product is cannabis and hemp or medicinal products. Accordingto embodiments, the perishable product is a floral product includingroses and cut flowers.

According to an embodiment of the invention, baffles to seal in contactwith the pallets to cause the air flow to be forced through the palletsare intended. These baffles may be fixed in place or can be rotated orshifted to seal the pallets during operation using manual or automatedcomponents.

According to an embodiment of the invention, protective coatings can beapplied to the walls of the container and/or semi-trailer, refrigerationequipment, shuttle conveyor, and/or any other materials that will comeinto contact with the sanitizing ingredients.

According to an embodiment of the invention, the modifications to thecontainer or semi-trailer can also include special venting of the gasfrom the unit prior to entry for removing the pallets. This ventingcould incorporate a catalytic converter in the case of ozone, or ascrubber that would neutralize any corrosive mists or fog.

Similarly, according to an embodiment of the invention, themodifications to the container or semi-trailer can also include specialtreatment of the condensate and washout drains for proper neutralizationand liquid transmission to the facility drains.

According to an embodiment, the methods and apparatus of the inventioncan include (a) moving each of the pallets into position and at theplenum within the modified mobile and/or prefabricated containers andsemi-trailers, and (b) after properly positioning each pallet adjacentto the plenum (within the modified and/or prefabricated container orsemi-trailer), creating a seal that matches the edge dimension of thegoods/vented boxes/packaging stacked on the pallets in order to optimizethe airflow across the goods and through the vented boxes/packaging forefficient and effective cooling, sanitizing and/or ripening.

According to an embodiment, a mechanism is further provided to movepallet closure pads to meet the pallets that have been loaded into theone of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container (or trailer), to create a seal to create apositive air flow plenum and thus force air through the pallets insteadof around. According to one embodiment, the mechanism to move the palletclosure pads may be operated by at least one of hydraulic means(cylinders), at least one mechanical device or drive (such as a pulleyor servo motor), or air pressure (inflatable pads or cushions). Whenloading or unloading the container, the mechanism releases the pads andbacks away from the pallets.

Another embodiment of the invention relates to using unconventionalmaterials to treat and cool the perishable product. For treatment,solutions of materials that include organic liquids such as alcoholshave excellent sanitizing properties. The electrical system for themobile container could require specifications for flammable componentsor modified atmosphere. Additionally, industrial gas such as nitrogencould be used to provide an inert atmosphere inside the container andalso be a component to aid the cooling process.

The various embodiments of the invention described herein allow forcooling, treating, processing, and/or packaging various perishableproducts, along with an overall system, product specific methods, andmodular interconnected apparatus designed to accomplish the treatment,cooling, packaging, and/or processing/handling in an efficient mannerwhile assuring the benefits of better, safer, longer lasting product.This includes longer shelf-life (lower respiration), lessspoilage/decay, less dehydration, timely treatments and packaging forcontrol of condition, quality, organoleptic characteristics, andripening.

Only exemplary embodiments of the present invention and but a fewexamples of its versatility are shown and described in the presentdisclosure. It is to be understood that the present invention is capableof use in various other combinations and environments and is capable ofchanges or modifications within the scope of the inventive concept asexpressed herein.

Although the foregoing description is directed to the preferredembodiments of the invention, it is noted that other variations andmodifications will be apparent to those skilled in the art and may bemade without departing from the spirit or scope of the invention.Moreover, features described in connection with one embodiment of theinvention may be used in conjunction with other embodiments, even if notexplicitly stated above.

1. An apparatus for processing and cooling a perishable product to itsintended temperature, the apparatus comprising: (A) one of (a) a mobilecontainer, (b) a semi-trailer, or (c) a prefabricated container, whichis modified to add high capacity refrigeration and high capacity airflowto perishable product, wherein the one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container includes at least onerefrigeration source that is configured to supply a cooled airflow tothe one of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container that is directed across the perishable productcontained within the one of (i) a mobile container, (ii) a semi-trailer,or (iii) a prefabricated container; and (B) one of (a) a mobilecontainer, (b) a semi-trailer, or (iii) a prefabricated container, whichis modified to include a process line to sort and functionally treat theperishable product.
 2. The apparatus according to claim 1, wherein theone of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container, which is modified to add high capacityrefrigeration and high capacity airflow is configured to be relocated toa production facility or a seasonal growing area for increased oryear-round utilization.
 3. The apparatus according to claim 1, whereinthe process line is configured to (i) transfer the product onto the lineand (ii) remove any debris and/or defects.
 4. The apparatus according toclaim 3, wherein the process line is further configured to apply atleast one of (i) a wet or dry wash, (ii) sanitization, (iii) cooling(iv) air drying, or (v) a combination thereof.
 5. The apparatusaccording to claim 1, further comprising a packaging line to package theproduct into final consumer packages.
 6. The apparatus according toclaim 1, wherein the perishable product includes one or more of (i)pre-packed product after harvesting, (ii) bulk packed product into aharvest container to supply to a packing line, and (iii) product packedinto a partial container that needs additional handling/processing stepsto complete the packing of the harvested product.
 7. The apparatusaccording to claim 1, further comprising one of (a) a mobile container,(b) a semi-trailer, or (c) a prefabricated container, which is modifiedto supply sanitizing substances to the perishable product.
 8. Theapparatus according to claim 1, wherein the one of (i) a mobilecontainer, (ii) a semi-trailer, or (iii) a prefabricated container,which is modified to add high capacity refrigeration and high capacityairflow further includes at least one treatment spraying system that isconfigured to supply at least one of (a) sanitizing substances to asurface of the perishable product contained within the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer, which is modified to add high capacity refrigeration and highcapacity airflow, and (b) conditioning or ripeness management substancesto a surface of the perishable product contained within the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer, which is modified to add high capacity refrigeration and highcapacity airflow.
 9. The apparatus according to claim 8, wherein thesanitizing substances include at least one of ozone, hydrogen peroxide,ionized hydrogen peroxide, ozonated water, ionized water, peraceticacid, sodium hypochlorite, ionized chlorinated water, electrochlorinatedwater, oxidizing materials, and any other form(s) (including ionized andoxidized forms) of these substances.
 10. The apparatus according toclaim 8, wherein the sanitizing substances are mixed with a carrier thatincludes one of air, industrial gas, water, or alcohol.
 11. Theapparatus according to claim 8, wherein the sanitizing substances areadded to recirculating air continually, intermittently, in stages,steps, cycles, or pulses.
 12. The apparatus according to claim 8,wherein at least one of the conditioning or ripeness managementsubstances is ethylene, ethephon, 1-MCP or 1-Methylcyclopropene, or asubstance that controls a ripening process or effects of ethylene. 13.The apparatus according to claim 1, wherein the high capacityrefrigeration provides about 5,000 to about 50,000 Btu's of coolingcapacity per hour per pallet of product, wherein the high capacityrefrigeration provides about 25,000 to about 45,000 Btu's of coolingcapacity per hour per pallet of product, or wherein the high capacityrefrigeration provides about 35,000 Btu's of cooling capacity per hourper pallet of product.
 14. The apparatus according to claim 1, whereinthe high capacity airflow provides about 200 to about 3,000 cubic feetper minute (cfm) of airflow per pallet of product, wherein the highcapacity airflow provides about 500 to about 1,000 cfm of airflow perpallet of product, or wherein the high capacity airflow provides about1,500 to about 3,000 cfm per pallet of product.
 15. The apparatusaccording to claim 1, wherein modifications to the one of (i) a mobilecontainer, (ii) a semi-trailer, or (iii) a prefabricated container,which is modified to add high capacity refrigeration and high capacityairflow include one or more of: (a) adding at least one refrigerationunit and air flow components along one or more sidewalls on an inside ofthe one of (i) a mobile container, (ii) a semi-trailer, or (iii) aprefabricated container for the cooling of at least a single row ofpallets of perishable product; (b) creating pop-out sidewalls and a roofmounted refrigeration unit, to enable horizontal cooling and treatmentair for a container or semi-trailer filled with at least two rowspallets of perishable product; (c) creating at least one pop-outsidewall and a wall mounted refrigeration unit, to enable horizontalcooling and treatment air for a container or semi-trailer filled with atleast two rows pallets of perishable product; (d) creating pop-outsidewalls and a corner mounted refrigeration unit, to enable horizontalcooling and treatment air for a container or semi-trailer filled with atleast two rows pallets of perishable product; and (e) attaching aplurality of refrigeration units to one or more sidewalls of the one of(i) a mobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer, wherein the one or more sidewalls have openings to enablehorizontal air to cool and to treat at least one row to at least tworows of pallets of perishable product and to return the air to theplurality of refrigeration units.
 16. The apparatus according to claim1, further comprising a shuttle conveyor to move perishable product intoand out of (A) the one of (a) a mobile container, (b) a semi-trailer, or(iii) a prefabricated container, which is modified to add high capacityrefrigeration and high capacity airflow, and (B) the one of (a) a mobilecontainer, (b) a semi-trailer, or (c) a prefabricated container, whichis modified to include a process line to sort and functionally treat theproduct.
 17. The apparatus according to claim 16, wherein the shuttleconveyor is at least one of (a) an in-and-out design, (b) a pass-throughdesign in which perishable product is passed-through from one end to anopposite end of each of the one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container, and (c) integratedwith a second shuttle conveyor that moves perishable product to an MAPapplication system.
 18. The apparatus according to claim 1, furthercomprising a secondary one of (a) a mobile container, (b) asemi-trailer, or (c) a prefabricated container, which is modified to addhigh capacity refrigeration and high capacity airflow to perishableproduct, wherein the secondary one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container includes at least onerefrigeration source that is configured to supply a cooled airflow tothe secondary one of (i) a mobile container, (ii) a semi-trailer, or(iii) a prefabricated container to the perishable product containedwithin the secondary one of (i) a mobile container, (ii) a semi-trailer,or (iii) a prefabricated container.
 19. The apparatus according to claim18, wherein the secondary one of (i) a mobile container, (ii) asemi-trailer, or (iii) a prefabricated container further includes atleast one treatment spraying system that is configured to supply atleast one of (a) sanitizing substances to a surface of the perishableproduct contained within the secondary one of (i) a mobile container,(ii) a semi-trailer, or (iii) a prefabricated container, and (b)conditioning or ripeness management substances to a surface of theperishable product contained within the secondary one of (i) a mobilecontainer, (ii) a semi-trailer, or (iii) a prefabricated container. 20.The apparatus according to claim 1, further comprising at least onemobile refrigerated container configured to provide cold storage for theperishable product prior to shipment.
 21. The apparatus according toclaim 1, wherein the perishable product includes one or more oftomatoes, berries, cherries, meat products, fresh cut flowers, cannabisproducts, hemp products, a protein including meat, fish, foul, vegetableprotein products, or other fruits and vegetables.
 22. An apparatus forprocessing and cooling a perishable product to its intended temperature,the apparatus comprising: (A) one of (a) a mobile container, (b) asemi-trailer, or (c) a prefabricated container, which is modified to addhigh capacity refrigeration and high capacity airflow to perishableproduct, wherein the one of (i) a mobile container, (ii) a semi-trailer,or (iii) a prefabricated container includes at least one refrigerationsource that is configured to supply a cooled airflow to the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer that is directed across the perishable product containedwithin the one of (i) a mobile container, (ii) a semi-trailer, or (iii)a prefabricated container; and (B) one of (a) a mobile container, (b) asemi-trailer, or (c) a prefabricated container, which is modified toinclude a packaging line to package the perishable product into finalconsumer packages.
 23. The apparatus according to claim 22, furtherincluding a process line to sort and functionally treat the product. 24.The apparatus according to claim 22, wherein the one of (a) a mobilecontainer, (b) a semi-trailer, or (c) a prefabricated container, whichis modified to include a packaging line is further modified to include aprocess line to sort and functionally treat the product.
 25. Theapparatus according to claim 22, wherein the perishable product includesone or more of (i) pre-packed product after harvesting, (ii) bulk packedproduct into a harvest container to supply to a packing line, and (iii)product packed into a partial container that needs additionalhandling/processing steps to complete the packing of the harvestedproduct.
 26. The apparatus according to claim 22, wherein the one of (i)a mobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer, which is modified to add high capacity refrigeration and highcapacity airflow further includes at least one treatment spraying systemthat is configured to supply at least one of (a) sanitizing substancesto a surface of the perishable product contained within the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer, which is modified to add high capacity refrigeration and highcapacity airflow, and (b) conditioning or ripeness management substancesto a surface of the perishable product contained within the one of (i) amobile container, (ii) a semi-trailer, or (iii) a prefabricatedcontainer, which is modified to add high capacity refrigeration and highcapacity airflow.
 27. A method of treating a perishable product using aplurality of independent modified or prefabricated containers orsemi-trailers, with each independent modified or prefabricated containeror semi-trailer of the plurality of independent modified orprefabricated containers or semi-trailers being (a) modified to provide(i) high capacity refrigeration and high capacity airflow, (ii) one ormore sanitizing treatments, (iii) a conditioning or ripeness managementprocess, (iv) a process line, (v) a packaging line, or (vi) acombination of one or more of (i), (ii), (iii), (iv), and (v), and (b)used for (i) cooling, (ii) sanitizing, (iii) controlling a conditioningor ripeness management process of the perishable product, (iv) sortingand functionally treating the product, (v) packaging the product intofinal consumer packages, and (vi) a combination of one or more of (i),(ii), (iii), (iv), and (v).
 28. The method according to claim 27,wherein the perishable product includes one or more of tomatoes,berries, cherries, meat products, fresh cut flowers, cannabis products,hemp products, a protein including meat, fish, foul, vegetable proteinproducts, or other fruits and vegetables.
 29. The method according toclaim 27, wherein a substance is directly applied using a carrier to asurface of the perishable product after harvesting and after wet or drywashing of the perishable product, wherein a predetermined amount of thesubstance is applied to the surface to substantially coat, contact, orcover the surface; and wherein the substance is applied (i) beforecooling of the perishable product, (ii) during cooling of the perishableproduct, or (iii) after cooling of the perishable product.
 30. Themethod according to claim 27, wherein the perishable product is treatedinside of a packaging mechanism or a film forming mechanism, wherein thefilm forming or packaging mechanism forms, seals, contains, or closes apackage around the perishable product, and the treatment occurs justprior to or simultaneous to when the package is formed around theperishable product.
 31. The method according to claim 29, wherein thecarrier is at least one of (i) a liquid, including ionized water oracidified water, (ii) a gas, including nitrogen or purified air, or(iii) combinations thereof.
 32. The method according to claim 27,further comprising incorporating detecting technology to directsubstance treatment, with said technology being configured to: (i)detect a surface area of the perishable product and adjusting an amountof a substance to be applied based on the detected surface area of theperishable product; (ii) detect a defect on a surface of the perishableproduct and applying a substance on the defect on the surface of theperishable product; or (iii) detect an amount of a surface of theperishable product that is covered by a substance, and directlyreapplying the substance to the surface of the perishable product whenthe amount of the substance on the surface of the perishable productdoes not meet a predetermined value.
 33. The method according to claim29, wherein the substance is (i) selected from the group consisting of asanitizer, an antifungal, an essential oil, a reducing agent, asurfactant, a humectant, a photosensitizer, a buffering agent, a mineralsalt, an aroma, a sweetener or flavoring agent, a sealing or coatingsubstance, an anti-browning substance, an ethylene scavenger, ethyleneblocking compound, a ripening agent, a nutritional substance, aprobiotic, a coloring, nano particles, phages, enzymes, sugar substance,an absorbent, a neutralizing agent, and an oxidizing agent, or (ii)selected from the group consisting of chlorine dioxide, hydrogenperoxide, peracetic acid, ozone, ionized water, lemon oil, orange oil,grapefruit oil, rosemary oil, sunflower oil, other fruit-derived oils,tea tree oil, cinnamon oil, eucalyptus oil, potassium oleate, sodiumdodecyl sulfate (SDS), ascorbic acid, citric acid, sodium bicarbonate,calcium phosphate, esters, linear terpenes, cyclic terpenes, alcohols,aldehydes, esters, ketones, lactones, thiols, rose oil, rose essence,air, and fruit essence.
 34. The method according to claim 29, whereinthe substance wet or dry washes, prevents moisture loss of theperishable product, slows senescence of the perishable product, is apreservative, is comprised of ionized water or ionized air, enhancescolor, enhances flavor, enhances aroma, enhances texture of theperishable product, acts as a pH buffer, breaks down biofilm on thesurface, or combinations thereof.
 35. The method according to claim 29,wherein the substance is a first substance, and the method furthercomprises directly applying a second substance which is different thanthe first substance to the surface of the perishable product atasynchronous points prior to final packaging of the perishable productusing a second carrier, wherein the second substance enhances theefficacy of the first substance.
 36. A system adaptable for specificperishable products, packaging designs, and operational flexibility, thesystem comprising: (a) at least one sanitization apparatus; (b) at leastone cooling apparatus; (c) at least one process line; and (d) at leastone packaging line, wherein air flow and cooling capacity is establishedto achieve a selected sanitizer recirculation and cooling rate, whereinsanitizer and cooling processes are controlled for designed purposes andcycles, wherein the at least one process line is configured to at leastone of sort and functionally treat the perishable products, and whereinthe at least one packaging line is configured to package the perishableproducts into final consumer packages.
 37. The system according to claim36, further comprising a modified atmosphere pallet (MAP) applicationsystem.
 38. The system according to claim 37, further comprising atleast one conveyor system to transport the perishable products betweenone or more of (i) the at least one sanitization apparatus, (ii) the atleast one cooling apparatus, (iii) the at least one process line, (iv)the at least one packaging line, and (v) the modified atmosphere pallet(MAP) application system.
 39. The system according to claim 36, whereinthe at least one sanitization apparatus and the at least one coolingapparatus are combined into a single container.
 40. The system accordingto claim 36, further comprising at least one mobile refrigeratedcontainer configured to provide cold storage for the perishable productsprior to shipment.
 41. The system according to claim 36, furthercomprising one or more robotic pallets configured to transport theperishable products between one or more of (i) the at least onesanitization apparatus, (ii) the at least one cooling apparatus, (iii)the at least one process line, and (iv) the at least one packaging line.42. The system according to claim 36, wherein at least one of (i) the atleast one sanitization apparatus and (ii) the at least one coolingapparatus comprises a modified mobile container, semi-trailer, orprefabricated container that is configured to be setup in closeproximity to a harvest location, such that a time from harvest to cooland shipment is substantially reduced by one or more hours up to 2 days.43. The system according to claim 36, wherein the perishable productsinclude one or more of (i) pre-packed product after harvesting, (ii)bulk packed product into a harvest container to supply to a packingline, and (iii) product packed into a partial container that needsadditional handling/processing steps to complete the packing of theharvested product.
 44. An overall system for automated postharvesthandling, treatment, precooling, and packaging for distribution ofproducts supporting production facilities, including field, greenhouse,or indoor growing operations, the system comprising: one or more mobile,portable modified or prefabricated containers; and one or moreconveyors, pallet shuttle apparatus, or robotic pallets interconnectingthe one or more mobile, portable modified or prefabricated containers,wherein the system uses prescribed methods and programmed apparatus toprovide product sanitizing, precooling, treating, handling, andpackaging of the products from receiving to loading and shipping. 45.The overall system according to claim 44, wherein the one or moremobile, portable modified or prefabricated containers includes at leastone pallet shuttle apparatus and comprises a pass-thru design to receiveproduct directly from a processing or packing line and to deliver theproduct from a discharge end directly to one of (i) an MAP system, (ii)a cold storage mobile unit, or (iii) loading and shipping.
 46. Theoverall system according to claim 44, wherein the products include oneor more of (i) pre-packed product after harvesting, (ii) bulk packedproduct into a harvest container to supply to a packing line, and (iii)product packed into a partial container that needs additionalhandling/processing steps to complete the packing of the harvestedproduct.